33
Chapter 1 Technical Administration Topics To hear audio, click on the box. Overview The higher you ascend on the enlisted ladder, the more valuable you are to the Navy. Advancement brings both increased rewards and responsibilities. You must be able to perform various administrative duties within the Construction Mechanic rate, such as opening and closing OPNAV 4790/2K and OPNAV 4790/CK Completed Maintenance Action orders, maintaining history jackets, updating preventive maintenance record cards, and repair parts. The type of activity to which you are attached will determine the way you should carry out your administrative responsibilities. Objectives When you have completed this chapter, you will be able to do the following: 1. Identify the personnel and their functions, and the required paperwork associated with a Battalion Equipment Maintenance Program. 2. Recognize the principles and techniques of administering the Civil Engineering Support Equipment (CESE) maintenance program. 3. Recognize key items of maintenance support required for the Civil Engineering Support Equipment (CESE) maintenance program. Prerequisites None 1.0.0 Maintenance Administration 2.0.0 Maintenance Support NAVEDTRA 14264A 1-1

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Chapter 1

Technical Administration

Topics

To hear audio click on the box

Overview The higher you ascend on the enlisted ladder the more valuable you are to the Navy Advancement brings both increased rewards and responsibilities You must be able to perform various administrative duties within the Construction Mechanic rate such as opening and closing OPNAV 47902K and OPNAV 4790CK Completed Maintenance Action orders maintaining history jackets updating preventive maintenance record cards and repair parts The type of activity to which you are attached will determine the way you should carry out your administrative responsibilities

Objectives When you have completed this chapter you will be able to do the following

1 Identify the personnel and their functions and the required paperwork associated with a Battalion Equipment Maintenance Program

2 Recognize the principles and techniques of administering the Civil Engineering Support Equipment (CESE) maintenance program

3 Recognize key items of maintenance support required for the Civil Engineering Support Equipment (CESE) maintenance program

Prerequisites None

100 Maintenance Administration

200 Maintenance Support

NAVEDTRA 14264A 1-1

null

2010-03-30T150404-0500

3748575

This course map shows all of the chapters in Construction Mechanic Basic The suggested training order begins at the bottom and proceeds up Skill levels increase as you advance on the course map

Automotive Chassis and Body

Brakes

Construction Equipment Power Trains C

Drive Lines Differentials Drive Axles and Power Train Accessories M

Automotive Clutches Transmissions and Transaxles

Hydraulic and Pneumatic Systems

Automotive Electrical Circuits and Wiring

B

A

Basic Automotive Electricity S

Cooling and Lubrication Systems I

Diesel Fuel Systems C

Gasoline Fuel Systems

Construction of an Internal Combustion Engine

Principles of an Internal Combustion Engine

Technical Administration

Features of this Manual This manual has several features which make it easy to use online

bull Figure and table numbers in the text are italicized The figure or table is either next to or below the text that refers to it

bull The first time a glossary term appears in the text it is bold and italicized When your cursor crosses over that word or phrase a popup box displays with the appropriate definition

bull Audio and video clips are included in the text with an italicized instruction telling you where to click to activate it

bull Review questions that apply to a section are listed under the Test Your Knowledge banner at the end of the section Select the answer you choose If the answer is correct you will be taken to the next section heading If the answer

NAVEDTRA 14264A 1-2

is incorrect you will be taken to the area in the chapter where the information is for review When you have completed your review select anywhere in that area to return to the review question Try to answer the question again

bull Review questions are included at the end of this chapter Select the answer you choose If the answer is correct you will be taken to the next question If the answer is incorrect you will be taken to the area in the chapter where the information is for review When you have completed your review select anywhere in that area to return to the review question Try to answer the question again

NAVEDTRA 14264A 1-3

100 MAINTENANCE ADMINISTRATION Administrative guidelines concerning Civil Engineering Support Equipment (CESE) maintenance are contained in Naval Facilities Publication 300 (NAVFAC P-300) Management of Civil Engineering Support Equipment and the most current version of Commander First Naval Construction Division 112002 (COMFIRSTNCDINST 112002)

110 Maintenance Organization The organization of equipment maintenance work centers varies in the following aspects

bull Number and types of assigned equipment

bull Number and experience of personnel

bull Work hours

bull Number of shifts

bull Environmental conditions

bull Mission of the activity The typical Naval Mobile Construction Battalionrsquos (NMCBrsquos) maintenance organization is divided into several shops

bull The Light Shop is responsible for the planned maintenance and breakdown repair of all equipment assigned by the Maintenance Supervisor (generally all equipment codes beginning with 0) The number of crews is dictated by manpower and equipment quantity assigned This shop conducts Preventive Corrective and Inactive Equipment Maintenance (IEM) per Naval Sea Systems Command Instruction 47908B (NAVSEAINST 47908B) on all Light Shop CESE assigned to IEM This shop also maintains repair parts for assigned CESE

bull The Heavy Shop is responsible for the planned maintenance and breakdown repair of all equipment assigned by the Maintenance Supervisor (generally all non-light shop equipment minus the 5000 shop equipment) The priority of this shop is generally in support of the battalionrsquos construction effort This shop conducts Preventive Corrective and IEM per NAVSEAINST 47908B on all Heavy Shop CESE assigned to IEM This shop also maintains repair parts for assigned CESE

bull The Support Shops are normally comprised of the 5000 Shop (EC 5000-5999) Steel Shop MR Shop Tire Shop and Paint Shop These shops are specialty shops that are tasked with supporting the other shops with their particular expertise These shops also maintain repair parts for assigned CESE

bull The Crane Shop is responsible for the planned maintenance and corrective repair of all cranes and ensuring all maintenance guidelines are adhered to per NAVFAC P-307

NAVEDTRA 14264A 1-4

NOTE

At no time will cranes be put in IEM Status I

All cranes will be kept alive and cycled per COMFIRSTNCDINST 112002 Cranes on deadline are maintained in IEM Status II until removed from deadline

The following personnel organization is based on a typical Naval Mobile Construction Battalion operation but the functions are applicable to small shops where one person may perform several functions

111 Maintenance SupervisorDivision Maintenance Chief

The Maintenance SupervisorDivision Maintenance Chief (A4) is usually the senior mechanic assigned to an activity normally a Construction Mechanic Senior Chief (CMCS) who has successfully completed the Shiprsquos Maintenance and Material Management (3-M) Personnel Qualifications Standards (PQS) up to Section 304 The A4 is tasked with ensuring proper 3-M maintenance and repair of all automotive construction and material and weight handling equipment assigned to the NMCBUnit Duties and responsibilities are described in COMFIRSTNCDINST 112002 and Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B

112 Work Center Supervisor

The Work Center Supervisor (WCS) functions under the supervision of the Maintenance SupervisorDivision Maintenance Chief The Supervisor is normally a Construction Mechanic Chief (CMC) who has successfully completed 3-M PQS up to Section 303 The WCS has all the administrative and military duties of a Platoon Commander in addition to the assigned functional responsibilities and Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B

The WCS uses SKED every week to develop the assigned shoprsquos Weekly 13 Week Accountability Log The A4Division Maintenance Chief and WCS ensures that project critical equipment has priority in the shop Responsibilities of the WCS are detailed in COMFIRSTNCDINST 112002

1121 Light Shop Work Center Supervisor

The Light Shop WCS is responsible to the Maintenance SupervisorDivision Maintenance Chief for scheduled Preventive Corrective and IEM maintenance requirements for over the road material handling equipment (MHE) and personnel carrying CESE

1122 Heavy Shop Work Center Supervisor

The Heavy Shop WCS is responsible to the Maintenance SupervisorDivision Maintenance Chief for scheduled Preventive Corrective IEM and field service maintenance on ALL CONSTRUCTION CESE

NAVEDTRA 14264A 1-5

1123 Crane Crew Work Center Supervisor

The Crane Crew WCS ensures that preventive and corrective maintenance are performed on all cranes assigned All scheduled preventive maintenance is performed as per Maintenance Requirement Card (MRC)

1124 Support Shop Work Center Supervisor

The Support Shop WCS is responsible to the Maintenance Supervisor for the maintenance and repair of CESE starting with an Equipment Code (EC) of ldquo5rdquo andor as directed by the Maintenance Supervisor The WCS identifies and coordinates all maintenance requirements through the shop that necessitate the CMEOCESWHTMR skill for completion with Dispatcher on Project and ldquoCrdquo assigned CESE Responsibilities of the various shops are detailed in COMFIRSTNCDINST 112002 and include the following shops

bull Machine Shop

bull Steel and Radiator Shop

bull Electrical Shop

bull Battery Shop

bull Paint Shop

bull Tire Shop

113 Inspector

Work Center Inspectors examine the equipment for additional required repairs when the CESE is scheduled for planned or corrective maintenance Inspectors work directly for and are responsible to the Maintenance SupervisorDivision Maintenance Chief They should be senior mechanics knowledgeable and proficient in their rating and should be able to clearly describe each repair action on the MRC Each piece of equipment is inspected after repairs are completed on the 2-Kilo by each work center Inspector to ensure that work is correctly completed

Thorough final inspection increases reliability and in turn reduces the mechanics workload Inspectors may perform minor repair work that pertains to inspection procedures only Inspectors should immediately notify the Maintenance Supervisor when suspected equipment abuse or recurring failures are discovered The inspector reviews technical manuals technical bulletins maintenance bulletins Advanced Change Notices (ACNs) and Feedback Report replies Inspectors ensure required annual safety inspections and hourlymileage repairsadjustments are completed in accordance with MRCs The Inspector ensures all collateral equipment is inspected for completeness deterioration preservation shelf life and proper stowage

114 Technical Librarian

The Technical Librarian is responsible to the Maintenance Supervisor for the pre-packed library which contains operational maintenance and parts manuals The Librarian establishes and enforces checkout procedures for all manuals and maintains all required reference materials needed to research and initiate part requisitions on Naval Supply (NAVSUP) Form 1250-2s The Technical Librarian normally researches NAVEDTRA 14264A 1-6

and prepares the NAVSUP Form 1250-2s to free floor mechanics to perform maintenance functions

115 Work Center Supervisor (3-M)

Work Center Supervisors are qualified and designated in writing They are responsible to the Division Officer via the Group Supervisor if applicable for the effective operation of the 3-M System within their respective Work Center Work Center Supervisor responsibilities are the following

bull Maintain a detailed working knowledge of all equipment deficiencies within the Work Center The Work Center Supervisor uses the Current Shiprsquos Maintenance Plan (CSMP) as a daily working document for the scheduling of any maintenance actions not included on the Preventive Maintenance Schedule (PMS) schedules

bull Schedule weekly Work Center maintenance and supervise its proper accomplishment

bull Ensure the status of Work Center planned maintenance is correctly reflected on the PMS schedules

bull Ensure the Division Officer or Group Supervisor if applicable is advised of all 3-M System activity within the Work Center

bull Maintain an adequate supply of 3-M System materials within the Work Center

bull Ensure prompt reporting of all material deficiencies and completed maintenance actions as required

bull Ensure all 3-M System documents submitted from the Work Center are correct legible and promptly prepared and submitted

bull Ensure maximum use of PMS as an aid for training personnel in maintenance procedures for equipment within the Work Center

bull Ensure 3-M System Work Center files publications MRC decks Tag Guide Lists (TGLs) and EGLs are complete and current

bull Review MRCs and promptly submit a PMS Feedback Report (FBR) whenever maintenance requirements are not fully understood errors are believed to exist maintenance requirements appear inadequate or excessive additional coverage is needed or performance of the maintenance requirement would cause a hazardous condition to exist

bull Ensure PMS covers all equipment in the Work Center Maintain an accurate and current List of Effective Pages (LOEP) by comparing the documentation with the actual equipment configuration Submit PMS FBR when changes to the LOEP are required Submit configuration change requests when appropriate

bull Ensure programmed Periodic Maintenance Requirements (PMRs) scheduled for ships force accomplishment are completed and reported in strict accordance with the PMR if applicable

bull Ensure proper testing and inspection of work done by outside activities prior to job acceptance

NAVEDTRA 14264A 1-7

bull Ensure delivery of test and measurement equipment and other portable support equipment to testing and calibration Work Centers as indicated on scheduling reports

120 Maintenance Categories The goal of maintenance is to keep equipment in a safe and serviceable condition at all times at reasonable costs and to detect minor deficiencies before they develop into costly repairs The Maintenance System of the Naval Construction Force (NCF) is predicated on three categories or levels of maintenance and 3-M Organizational Intermediate and Depot The category of repairs performed is determined by the following

bull Nature of the repair

bull Level of repair parts support tools equipment and time available

bull Personnel capabilities

bull Tactical situation

An activitys range of repair parts support is keyed to the authorized level of maintenance

121 Organizational Maintenance

Organizational maintenance is that maintenance which is the responsibility of and performed by the operator and scheduled preventive maintenance services performed by trained personnel Organizational maintenance consists of proper equipment operation safety and serviceability inspections lubrication minor adjustments and services in accordance with the MRC Organizational maintenance is divided into operator and preventive maintenance as specified below

1211 Operator Maintenance

Each operator is required to perform work needed to maintain his or her vehicle in a clean safe and serviceable condition Operator maintenance includes the daily inspections before during and after operation It also includes periodic lubrication and adjustments These requirements are completed utilizing the pertinent MRC Operator maintenance is performed to ensure early detection of deficiencies

1212 Preventive Maintenance

Preventive maintenance is that maintenance which is scheduled for the purpose of maximizing equipment availability and minimizing repair costs Preventive maintenance consists of safety and mechanical inspections lubrication and services and adjustments beyond an operators responsibility Operators should assist with this work unless directed otherwise Maintenance support requiring more extensive services is categorized as Corrective level maintenance

122 Corrective Maintenance

Corrective maintenance is that maintenance which is the responsibility of and performed in any designated maintenance shop The extent of corrective maintenance

NAVEDTRA 14264A 1-8

encompasses the removal replacement repair alteration calibration modification and the rebuild and overhaul of individual assemblies subassemblies and components Although the rebuild and overhaul of major assemblies are included only essential repairs should be accomplished to ensure safe and serviceable equipment Equipment that requires extensive repairs or numerous assembly rebuilds will not be repaired without prior approval by higher authority Corrective maintenance requires a higher degree of skill than organizational maintenance and a larger assortment of repair parts and more precision tools and test equipment

To preclude the possibility of the installation of expensive components on equipment which may be scheduled for excess survey or overhaul field units must request authority from the respective Regimental (R43) Equipment Office representative prior to the purchase of component parts costing in excess of $1000 or a total repair cost in excess of $2500

123 Depot Maintenance

Depot maintenance is that maintenance performed on equipment that requires major overhaul or comprehensive restoration to a degree necessary to restore the entire unit to a like-new condition

130 Maintenance Scheduling

131 Scheduling and Shop Control

An effective and efficient maintenance program requires the establishment and upkeep of a preventive maintenance scheduling system and a sound shop control procedure Vehicles and equipment should be scheduled for inspection and servicing in accordance with the time mileage and operating hours prescribed in NAVFAC P-300 Management of Civil Engineering Support Equipment and the Material Maintenance Management Program (3M) As a minimum the schedule should ensure that each vehicle is inspected for safety at least every 12 months or 12000 miles whichever occurs first The schedule can be formulated as follows

1 Determine the number of service intervals per year per vehicle by determining each vehiclersquos estimated annual miles and then dividing by the manufacturerrsquos recommended service interval

2 Develop the number of working days between each inspection (designated inspection group) for each vehicle by dividing the number of working days per year (250) by the number of service intervals per year

3 Establish a schedule from this determination that provides a quota of vehicles for inspection daily and a balanced shop workload

Use an electronic record to track service intervals and service performed The record should include the following

bull USN

bull EC

bull Make

bull Model NAVEDTRA 14264A 1-9

bull Year

bull Estimated annual mileshours

bull Type of service

bull Date

bull Cumulative mileage or hours

bull Miles or hours of operation

bull Miles or hours operated or a specified interval

132 Shop Workload

The best method for accomplishing positive direction of shop workload is to identify and keep the following information current

bull Available work force by work center

bull Vehiclesequipment awaiting input by work center

bull Vehiclesequipment in process by work center

bull Vehiclesequipment deadlined for parts cannibalization is not a normal acceptable business practice replacement parts whether new rebuilt or refurbished or reconditioned will equal or exceed OEM standards

bull Vehiclesequipment awaiting outgoing inspection

bull Vehiclesequipment awaiting customer pickup

bull Work performed by outside contractor

133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures

Figure 1-1 illustrates recommended SRO flow procedures See NAVFAC P-300 Management of Civil Engineering Support Equipment for details on preparing SROs

NAVEDTRA 14264A 1-10

Customer brings vehicle

Customer completes hard card noting deficiencies

Will work exceed

3 hours

SRO prepared

Work performed

by in-house shop

SRO amp vehicle assigned to technician

Work accomplished

Work inspected

Other shop within

activity

CommercialContractor

OtherGovernment

Agency

Refer to P-300 4-195J

Refer to P-300 4-195H

Refer to P-300 4-195I

Is equipmentOwned byAnother Activity

Copies of SRO properly routed

Vehicle returned to customer

Refer to P-300

4-195G

Work assigned to technician

Work accomplished

Work inspected

SRO Process

Yes

No

No

No

No No No

Yes

Yes

YesYesYes

Figure 1-1 - Flow chart for Shop Repair Orders

134 Supply Support

For a maintenance organization to perform effectively it must receive responsive repair parts support This support requires a high degree of cooperation and communication between the management and staff of the shop and the shop store and between the Public Works Officer and the Supply Officer

The responsibilities involved must be understood and fulfilled Commander Naval Facilities Engineering Command (COMNAVFACENGCOM) and Commander Naval Supply Systems Command (COMNAVSUPSYSCOM) have recognized these understandings and promulgated them as policy outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment

1341 Public Works Responsibility to the Supply Department

bull Ensure that all initial support repair parts received in Public Works are turned over to the Supply Department for inventory control and accountability Initial support repair parts intended for activity stock should not be retained in the

NAVEDTRA 14264A 1-11

physical custody or records of the Supply Department once issued to the end user

bull Provide information regarding repair parts requirements needed to support vehiclesequipment on hand or for any new vehicleequipment received (Requirements would normally be generated from actual operational experience or through normal routine inspection of equipment)

bull Furnish advance information regarding repair parts requirements for scheduled overhauls (Requirements would be generated in the same manner outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment)

bull Provide technical assistance to the Transportation Shop store in identifying parts and insurance items and in determining parts interchangeability

bull Advise shop store of equipment scheduled for disposal or phase out and assist in identifying stocked items which should be eliminated from the shop store

bull In the absence of stock items provide end use Operation and Maintenance Navy (OampM N) funds to permit procurement and delivery of repair parts required for work in progress or for subsequent scheduled services and repair for which job orders have been issued

bull Conduct periodic follow-up of shop store parts orders (after required delivery date has passed) to ensure that appropriate action has been taken to reduce further delay

bull Encourage active coordinationcommunications between Public Works and Supply Department personnel

1342 Supply Department Responsibility to Public Works (Transportation)

bull Provide for the timeliest method of repair parts support through the use of available stock system stocks or purchase action using imprest fund or blanket purchase authority and indefinite delivery parts contracts (IDTC) when practical

bull Perform technical research for parts identification and to determine part numbers interchangeability and cross-referenced parts numbers

bull Collaborate with Public Works in establishing stock levels in support of current and projected vehicleequipment inventories

bull Record parts usage data for subsequent stock range and depth adjustments

bull Expedite local procurement action for immediate issue requirements when parts required are not readily available in the shop store or main supply department

bull Review outstanding requisitions regularly to ensure that status received indicates satisfactory supply action is in progress Follow up as necessary to obtain delivery status

bull Advise Public Works personnel promptly indicating delivery date(s) of requested repair parts

NAVEDTRA 14264A 1-12

bull Assume responsibility for staging of material by segregating material receipts applicable to specific repair jobs and advising the shop maintenance supervisor of material status

bull Encourage active coordinationcommunications between Supply Department and Public Works personnel

1343 Technical Parts Ordering Data

Surveys conducted by COMNAVFACENGCOM into the breakdown of repair parts support have revealed that much delay and downtime are caused by the mechanics failure to provide adequate technical data when requesting parts It should be standard practice in all maintenance shops to provide shop stores with the following information for all but common hardware and bulk material

bull Description of Major Unit Describe the vehicle or equipment unit for which the part is applicable such as Truck l2 ton 4 x 2 5000GVW

bull Manufacturer of Major Unit Give the make

bull Model of Major Unit Give manufacturers model designation

bull Year of Manufacture or Model Year Determine from nameplate

bull Vehicle Identification Number (VIN) Determine from nameplate

bull Description of Component Describe major component for which the part is required For example Engine V8 260 cubic inches Transmission Automatic 5 speed Allison Model AT-545 Component identification can be determined from manufacturers component line set lists provided with all new equipment (Manufacturers line set lists should be filed in the equipment history record jacket)

bull Manufacturer of Component Give make of major component when other than make of major unit

bull Serial Number of Component Give serial number from component nameplate where applicable

bull Description of Part Give full description of part using standard nomenclature with noun name first followed by descriptive modifiers such as sprocket camshaft kit carburetor Provide the part name when available however the correct part name is the responsibility of the parts person and should be verified Part numbers should be recorded on the SRO for future reference This practice saves research time for the parts person

135 Maintenance Forms

Proper use of appropriate forms is important to keep equipment maintained

1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)

The Operators Inspection Guide and Trouble Report is used by operators of motor vehicles to indicate the items they are required to inspect before and after operation It also serves as a means of transmitting information regarding deficiencies detected

NAVEDTRA 14264A 1-13

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  101. dQuestionCMB01PC11a4
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  102. dQuestionCMB01PC12a1
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  103. dQuestionCMB01PC12a2
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  104. dQuestionCMB01PC12a3
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  105. dQuestionCMB01PC12a4
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  106. dQuestionCMB01PC13a1
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  107. dQuestionCMB01PC13a2
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  108. dQuestionCMB01PC13a3
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  110. dQuestionCMB01PC14a1
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  111. dQuestionCMB01PC14a2
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  112. dQuestionCMB01PC14a3
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  113. dQuestionCMB01PC14a4
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  114. dQuestionCMB01PC15a1
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  115. dQuestionCMB01PC15a2
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  116. dQuestionCMB01PC15a3
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  117. dQuestionCMB01PC15a4
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  118. dQuestionCMB01PC16a1
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  119. dQuestionCMB01PC16a2
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  143. txtCourse
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  145. txtChapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  146. txtPage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  147. txtDescription
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  148. txtCorrection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

This course map shows all of the chapters in Construction Mechanic Basic The suggested training order begins at the bottom and proceeds up Skill levels increase as you advance on the course map

Automotive Chassis and Body

Brakes

Construction Equipment Power Trains C

Drive Lines Differentials Drive Axles and Power Train Accessories M

Automotive Clutches Transmissions and Transaxles

Hydraulic and Pneumatic Systems

Automotive Electrical Circuits and Wiring

B

A

Basic Automotive Electricity S

Cooling and Lubrication Systems I

Diesel Fuel Systems C

Gasoline Fuel Systems

Construction of an Internal Combustion Engine

Principles of an Internal Combustion Engine

Technical Administration

Features of this Manual This manual has several features which make it easy to use online

bull Figure and table numbers in the text are italicized The figure or table is either next to or below the text that refers to it

bull The first time a glossary term appears in the text it is bold and italicized When your cursor crosses over that word or phrase a popup box displays with the appropriate definition

bull Audio and video clips are included in the text with an italicized instruction telling you where to click to activate it

bull Review questions that apply to a section are listed under the Test Your Knowledge banner at the end of the section Select the answer you choose If the answer is correct you will be taken to the next section heading If the answer

NAVEDTRA 14264A 1-2

is incorrect you will be taken to the area in the chapter where the information is for review When you have completed your review select anywhere in that area to return to the review question Try to answer the question again

bull Review questions are included at the end of this chapter Select the answer you choose If the answer is correct you will be taken to the next question If the answer is incorrect you will be taken to the area in the chapter where the information is for review When you have completed your review select anywhere in that area to return to the review question Try to answer the question again

NAVEDTRA 14264A 1-3

100 MAINTENANCE ADMINISTRATION Administrative guidelines concerning Civil Engineering Support Equipment (CESE) maintenance are contained in Naval Facilities Publication 300 (NAVFAC P-300) Management of Civil Engineering Support Equipment and the most current version of Commander First Naval Construction Division 112002 (COMFIRSTNCDINST 112002)

110 Maintenance Organization The organization of equipment maintenance work centers varies in the following aspects

bull Number and types of assigned equipment

bull Number and experience of personnel

bull Work hours

bull Number of shifts

bull Environmental conditions

bull Mission of the activity The typical Naval Mobile Construction Battalionrsquos (NMCBrsquos) maintenance organization is divided into several shops

bull The Light Shop is responsible for the planned maintenance and breakdown repair of all equipment assigned by the Maintenance Supervisor (generally all equipment codes beginning with 0) The number of crews is dictated by manpower and equipment quantity assigned This shop conducts Preventive Corrective and Inactive Equipment Maintenance (IEM) per Naval Sea Systems Command Instruction 47908B (NAVSEAINST 47908B) on all Light Shop CESE assigned to IEM This shop also maintains repair parts for assigned CESE

bull The Heavy Shop is responsible for the planned maintenance and breakdown repair of all equipment assigned by the Maintenance Supervisor (generally all non-light shop equipment minus the 5000 shop equipment) The priority of this shop is generally in support of the battalionrsquos construction effort This shop conducts Preventive Corrective and IEM per NAVSEAINST 47908B on all Heavy Shop CESE assigned to IEM This shop also maintains repair parts for assigned CESE

bull The Support Shops are normally comprised of the 5000 Shop (EC 5000-5999) Steel Shop MR Shop Tire Shop and Paint Shop These shops are specialty shops that are tasked with supporting the other shops with their particular expertise These shops also maintain repair parts for assigned CESE

bull The Crane Shop is responsible for the planned maintenance and corrective repair of all cranes and ensuring all maintenance guidelines are adhered to per NAVFAC P-307

NAVEDTRA 14264A 1-4

NOTE

At no time will cranes be put in IEM Status I

All cranes will be kept alive and cycled per COMFIRSTNCDINST 112002 Cranes on deadline are maintained in IEM Status II until removed from deadline

The following personnel organization is based on a typical Naval Mobile Construction Battalion operation but the functions are applicable to small shops where one person may perform several functions

111 Maintenance SupervisorDivision Maintenance Chief

The Maintenance SupervisorDivision Maintenance Chief (A4) is usually the senior mechanic assigned to an activity normally a Construction Mechanic Senior Chief (CMCS) who has successfully completed the Shiprsquos Maintenance and Material Management (3-M) Personnel Qualifications Standards (PQS) up to Section 304 The A4 is tasked with ensuring proper 3-M maintenance and repair of all automotive construction and material and weight handling equipment assigned to the NMCBUnit Duties and responsibilities are described in COMFIRSTNCDINST 112002 and Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B

112 Work Center Supervisor

The Work Center Supervisor (WCS) functions under the supervision of the Maintenance SupervisorDivision Maintenance Chief The Supervisor is normally a Construction Mechanic Chief (CMC) who has successfully completed 3-M PQS up to Section 303 The WCS has all the administrative and military duties of a Platoon Commander in addition to the assigned functional responsibilities and Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B

The WCS uses SKED every week to develop the assigned shoprsquos Weekly 13 Week Accountability Log The A4Division Maintenance Chief and WCS ensures that project critical equipment has priority in the shop Responsibilities of the WCS are detailed in COMFIRSTNCDINST 112002

1121 Light Shop Work Center Supervisor

The Light Shop WCS is responsible to the Maintenance SupervisorDivision Maintenance Chief for scheduled Preventive Corrective and IEM maintenance requirements for over the road material handling equipment (MHE) and personnel carrying CESE

1122 Heavy Shop Work Center Supervisor

The Heavy Shop WCS is responsible to the Maintenance SupervisorDivision Maintenance Chief for scheduled Preventive Corrective IEM and field service maintenance on ALL CONSTRUCTION CESE

NAVEDTRA 14264A 1-5

1123 Crane Crew Work Center Supervisor

The Crane Crew WCS ensures that preventive and corrective maintenance are performed on all cranes assigned All scheduled preventive maintenance is performed as per Maintenance Requirement Card (MRC)

1124 Support Shop Work Center Supervisor

The Support Shop WCS is responsible to the Maintenance Supervisor for the maintenance and repair of CESE starting with an Equipment Code (EC) of ldquo5rdquo andor as directed by the Maintenance Supervisor The WCS identifies and coordinates all maintenance requirements through the shop that necessitate the CMEOCESWHTMR skill for completion with Dispatcher on Project and ldquoCrdquo assigned CESE Responsibilities of the various shops are detailed in COMFIRSTNCDINST 112002 and include the following shops

bull Machine Shop

bull Steel and Radiator Shop

bull Electrical Shop

bull Battery Shop

bull Paint Shop

bull Tire Shop

113 Inspector

Work Center Inspectors examine the equipment for additional required repairs when the CESE is scheduled for planned or corrective maintenance Inspectors work directly for and are responsible to the Maintenance SupervisorDivision Maintenance Chief They should be senior mechanics knowledgeable and proficient in their rating and should be able to clearly describe each repair action on the MRC Each piece of equipment is inspected after repairs are completed on the 2-Kilo by each work center Inspector to ensure that work is correctly completed

Thorough final inspection increases reliability and in turn reduces the mechanics workload Inspectors may perform minor repair work that pertains to inspection procedures only Inspectors should immediately notify the Maintenance Supervisor when suspected equipment abuse or recurring failures are discovered The inspector reviews technical manuals technical bulletins maintenance bulletins Advanced Change Notices (ACNs) and Feedback Report replies Inspectors ensure required annual safety inspections and hourlymileage repairsadjustments are completed in accordance with MRCs The Inspector ensures all collateral equipment is inspected for completeness deterioration preservation shelf life and proper stowage

114 Technical Librarian

The Technical Librarian is responsible to the Maintenance Supervisor for the pre-packed library which contains operational maintenance and parts manuals The Librarian establishes and enforces checkout procedures for all manuals and maintains all required reference materials needed to research and initiate part requisitions on Naval Supply (NAVSUP) Form 1250-2s The Technical Librarian normally researches NAVEDTRA 14264A 1-6

and prepares the NAVSUP Form 1250-2s to free floor mechanics to perform maintenance functions

115 Work Center Supervisor (3-M)

Work Center Supervisors are qualified and designated in writing They are responsible to the Division Officer via the Group Supervisor if applicable for the effective operation of the 3-M System within their respective Work Center Work Center Supervisor responsibilities are the following

bull Maintain a detailed working knowledge of all equipment deficiencies within the Work Center The Work Center Supervisor uses the Current Shiprsquos Maintenance Plan (CSMP) as a daily working document for the scheduling of any maintenance actions not included on the Preventive Maintenance Schedule (PMS) schedules

bull Schedule weekly Work Center maintenance and supervise its proper accomplishment

bull Ensure the status of Work Center planned maintenance is correctly reflected on the PMS schedules

bull Ensure the Division Officer or Group Supervisor if applicable is advised of all 3-M System activity within the Work Center

bull Maintain an adequate supply of 3-M System materials within the Work Center

bull Ensure prompt reporting of all material deficiencies and completed maintenance actions as required

bull Ensure all 3-M System documents submitted from the Work Center are correct legible and promptly prepared and submitted

bull Ensure maximum use of PMS as an aid for training personnel in maintenance procedures for equipment within the Work Center

bull Ensure 3-M System Work Center files publications MRC decks Tag Guide Lists (TGLs) and EGLs are complete and current

bull Review MRCs and promptly submit a PMS Feedback Report (FBR) whenever maintenance requirements are not fully understood errors are believed to exist maintenance requirements appear inadequate or excessive additional coverage is needed or performance of the maintenance requirement would cause a hazardous condition to exist

bull Ensure PMS covers all equipment in the Work Center Maintain an accurate and current List of Effective Pages (LOEP) by comparing the documentation with the actual equipment configuration Submit PMS FBR when changes to the LOEP are required Submit configuration change requests when appropriate

bull Ensure programmed Periodic Maintenance Requirements (PMRs) scheduled for ships force accomplishment are completed and reported in strict accordance with the PMR if applicable

bull Ensure proper testing and inspection of work done by outside activities prior to job acceptance

NAVEDTRA 14264A 1-7

bull Ensure delivery of test and measurement equipment and other portable support equipment to testing and calibration Work Centers as indicated on scheduling reports

120 Maintenance Categories The goal of maintenance is to keep equipment in a safe and serviceable condition at all times at reasonable costs and to detect minor deficiencies before they develop into costly repairs The Maintenance System of the Naval Construction Force (NCF) is predicated on three categories or levels of maintenance and 3-M Organizational Intermediate and Depot The category of repairs performed is determined by the following

bull Nature of the repair

bull Level of repair parts support tools equipment and time available

bull Personnel capabilities

bull Tactical situation

An activitys range of repair parts support is keyed to the authorized level of maintenance

121 Organizational Maintenance

Organizational maintenance is that maintenance which is the responsibility of and performed by the operator and scheduled preventive maintenance services performed by trained personnel Organizational maintenance consists of proper equipment operation safety and serviceability inspections lubrication minor adjustments and services in accordance with the MRC Organizational maintenance is divided into operator and preventive maintenance as specified below

1211 Operator Maintenance

Each operator is required to perform work needed to maintain his or her vehicle in a clean safe and serviceable condition Operator maintenance includes the daily inspections before during and after operation It also includes periodic lubrication and adjustments These requirements are completed utilizing the pertinent MRC Operator maintenance is performed to ensure early detection of deficiencies

1212 Preventive Maintenance

Preventive maintenance is that maintenance which is scheduled for the purpose of maximizing equipment availability and minimizing repair costs Preventive maintenance consists of safety and mechanical inspections lubrication and services and adjustments beyond an operators responsibility Operators should assist with this work unless directed otherwise Maintenance support requiring more extensive services is categorized as Corrective level maintenance

122 Corrective Maintenance

Corrective maintenance is that maintenance which is the responsibility of and performed in any designated maintenance shop The extent of corrective maintenance

NAVEDTRA 14264A 1-8

encompasses the removal replacement repair alteration calibration modification and the rebuild and overhaul of individual assemblies subassemblies and components Although the rebuild and overhaul of major assemblies are included only essential repairs should be accomplished to ensure safe and serviceable equipment Equipment that requires extensive repairs or numerous assembly rebuilds will not be repaired without prior approval by higher authority Corrective maintenance requires a higher degree of skill than organizational maintenance and a larger assortment of repair parts and more precision tools and test equipment

To preclude the possibility of the installation of expensive components on equipment which may be scheduled for excess survey or overhaul field units must request authority from the respective Regimental (R43) Equipment Office representative prior to the purchase of component parts costing in excess of $1000 or a total repair cost in excess of $2500

123 Depot Maintenance

Depot maintenance is that maintenance performed on equipment that requires major overhaul or comprehensive restoration to a degree necessary to restore the entire unit to a like-new condition

130 Maintenance Scheduling

131 Scheduling and Shop Control

An effective and efficient maintenance program requires the establishment and upkeep of a preventive maintenance scheduling system and a sound shop control procedure Vehicles and equipment should be scheduled for inspection and servicing in accordance with the time mileage and operating hours prescribed in NAVFAC P-300 Management of Civil Engineering Support Equipment and the Material Maintenance Management Program (3M) As a minimum the schedule should ensure that each vehicle is inspected for safety at least every 12 months or 12000 miles whichever occurs first The schedule can be formulated as follows

1 Determine the number of service intervals per year per vehicle by determining each vehiclersquos estimated annual miles and then dividing by the manufacturerrsquos recommended service interval

2 Develop the number of working days between each inspection (designated inspection group) for each vehicle by dividing the number of working days per year (250) by the number of service intervals per year

3 Establish a schedule from this determination that provides a quota of vehicles for inspection daily and a balanced shop workload

Use an electronic record to track service intervals and service performed The record should include the following

bull USN

bull EC

bull Make

bull Model NAVEDTRA 14264A 1-9

bull Year

bull Estimated annual mileshours

bull Type of service

bull Date

bull Cumulative mileage or hours

bull Miles or hours of operation

bull Miles or hours operated or a specified interval

132 Shop Workload

The best method for accomplishing positive direction of shop workload is to identify and keep the following information current

bull Available work force by work center

bull Vehiclesequipment awaiting input by work center

bull Vehiclesequipment in process by work center

bull Vehiclesequipment deadlined for parts cannibalization is not a normal acceptable business practice replacement parts whether new rebuilt or refurbished or reconditioned will equal or exceed OEM standards

bull Vehiclesequipment awaiting outgoing inspection

bull Vehiclesequipment awaiting customer pickup

bull Work performed by outside contractor

133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures

Figure 1-1 illustrates recommended SRO flow procedures See NAVFAC P-300 Management of Civil Engineering Support Equipment for details on preparing SROs

NAVEDTRA 14264A 1-10

Customer brings vehicle

Customer completes hard card noting deficiencies

Will work exceed

3 hours

SRO prepared

Work performed

by in-house shop

SRO amp vehicle assigned to technician

Work accomplished

Work inspected

Other shop within

activity

CommercialContractor

OtherGovernment

Agency

Refer to P-300 4-195J

Refer to P-300 4-195H

Refer to P-300 4-195I

Is equipmentOwned byAnother Activity

Copies of SRO properly routed

Vehicle returned to customer

Refer to P-300

4-195G

Work assigned to technician

Work accomplished

Work inspected

SRO Process

Yes

No

No

No

No No No

Yes

Yes

YesYesYes

Figure 1-1 - Flow chart for Shop Repair Orders

134 Supply Support

For a maintenance organization to perform effectively it must receive responsive repair parts support This support requires a high degree of cooperation and communication between the management and staff of the shop and the shop store and between the Public Works Officer and the Supply Officer

The responsibilities involved must be understood and fulfilled Commander Naval Facilities Engineering Command (COMNAVFACENGCOM) and Commander Naval Supply Systems Command (COMNAVSUPSYSCOM) have recognized these understandings and promulgated them as policy outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment

1341 Public Works Responsibility to the Supply Department

bull Ensure that all initial support repair parts received in Public Works are turned over to the Supply Department for inventory control and accountability Initial support repair parts intended for activity stock should not be retained in the

NAVEDTRA 14264A 1-11

physical custody or records of the Supply Department once issued to the end user

bull Provide information regarding repair parts requirements needed to support vehiclesequipment on hand or for any new vehicleequipment received (Requirements would normally be generated from actual operational experience or through normal routine inspection of equipment)

bull Furnish advance information regarding repair parts requirements for scheduled overhauls (Requirements would be generated in the same manner outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment)

bull Provide technical assistance to the Transportation Shop store in identifying parts and insurance items and in determining parts interchangeability

bull Advise shop store of equipment scheduled for disposal or phase out and assist in identifying stocked items which should be eliminated from the shop store

bull In the absence of stock items provide end use Operation and Maintenance Navy (OampM N) funds to permit procurement and delivery of repair parts required for work in progress or for subsequent scheduled services and repair for which job orders have been issued

bull Conduct periodic follow-up of shop store parts orders (after required delivery date has passed) to ensure that appropriate action has been taken to reduce further delay

bull Encourage active coordinationcommunications between Public Works and Supply Department personnel

1342 Supply Department Responsibility to Public Works (Transportation)

bull Provide for the timeliest method of repair parts support through the use of available stock system stocks or purchase action using imprest fund or blanket purchase authority and indefinite delivery parts contracts (IDTC) when practical

bull Perform technical research for parts identification and to determine part numbers interchangeability and cross-referenced parts numbers

bull Collaborate with Public Works in establishing stock levels in support of current and projected vehicleequipment inventories

bull Record parts usage data for subsequent stock range and depth adjustments

bull Expedite local procurement action for immediate issue requirements when parts required are not readily available in the shop store or main supply department

bull Review outstanding requisitions regularly to ensure that status received indicates satisfactory supply action is in progress Follow up as necessary to obtain delivery status

bull Advise Public Works personnel promptly indicating delivery date(s) of requested repair parts

NAVEDTRA 14264A 1-12

bull Assume responsibility for staging of material by segregating material receipts applicable to specific repair jobs and advising the shop maintenance supervisor of material status

bull Encourage active coordinationcommunications between Supply Department and Public Works personnel

1343 Technical Parts Ordering Data

Surveys conducted by COMNAVFACENGCOM into the breakdown of repair parts support have revealed that much delay and downtime are caused by the mechanics failure to provide adequate technical data when requesting parts It should be standard practice in all maintenance shops to provide shop stores with the following information for all but common hardware and bulk material

bull Description of Major Unit Describe the vehicle or equipment unit for which the part is applicable such as Truck l2 ton 4 x 2 5000GVW

bull Manufacturer of Major Unit Give the make

bull Model of Major Unit Give manufacturers model designation

bull Year of Manufacture or Model Year Determine from nameplate

bull Vehicle Identification Number (VIN) Determine from nameplate

bull Description of Component Describe major component for which the part is required For example Engine V8 260 cubic inches Transmission Automatic 5 speed Allison Model AT-545 Component identification can be determined from manufacturers component line set lists provided with all new equipment (Manufacturers line set lists should be filed in the equipment history record jacket)

bull Manufacturer of Component Give make of major component when other than make of major unit

bull Serial Number of Component Give serial number from component nameplate where applicable

bull Description of Part Give full description of part using standard nomenclature with noun name first followed by descriptive modifiers such as sprocket camshaft kit carburetor Provide the part name when available however the correct part name is the responsibility of the parts person and should be verified Part numbers should be recorded on the SRO for future reference This practice saves research time for the parts person

135 Maintenance Forms

Proper use of appropriate forms is important to keep equipment maintained

1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)

The Operators Inspection Guide and Trouble Report is used by operators of motor vehicles to indicate the items they are required to inspect before and after operation It also serves as a means of transmitting information regarding deficiencies detected

NAVEDTRA 14264A 1-13

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  62. dQuestionCMB01PC2a1
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  110. dQuestionCMB01PC14a1
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  142. txtRate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  143. txtCourse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  144. txtDate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  145. txtChapter
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  147. txtDescription
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  148. txtCorrection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

is incorrect you will be taken to the area in the chapter where the information is for review When you have completed your review select anywhere in that area to return to the review question Try to answer the question again

bull Review questions are included at the end of this chapter Select the answer you choose If the answer is correct you will be taken to the next question If the answer is incorrect you will be taken to the area in the chapter where the information is for review When you have completed your review select anywhere in that area to return to the review question Try to answer the question again

NAVEDTRA 14264A 1-3

100 MAINTENANCE ADMINISTRATION Administrative guidelines concerning Civil Engineering Support Equipment (CESE) maintenance are contained in Naval Facilities Publication 300 (NAVFAC P-300) Management of Civil Engineering Support Equipment and the most current version of Commander First Naval Construction Division 112002 (COMFIRSTNCDINST 112002)

110 Maintenance Organization The organization of equipment maintenance work centers varies in the following aspects

bull Number and types of assigned equipment

bull Number and experience of personnel

bull Work hours

bull Number of shifts

bull Environmental conditions

bull Mission of the activity The typical Naval Mobile Construction Battalionrsquos (NMCBrsquos) maintenance organization is divided into several shops

bull The Light Shop is responsible for the planned maintenance and breakdown repair of all equipment assigned by the Maintenance Supervisor (generally all equipment codes beginning with 0) The number of crews is dictated by manpower and equipment quantity assigned This shop conducts Preventive Corrective and Inactive Equipment Maintenance (IEM) per Naval Sea Systems Command Instruction 47908B (NAVSEAINST 47908B) on all Light Shop CESE assigned to IEM This shop also maintains repair parts for assigned CESE

bull The Heavy Shop is responsible for the planned maintenance and breakdown repair of all equipment assigned by the Maintenance Supervisor (generally all non-light shop equipment minus the 5000 shop equipment) The priority of this shop is generally in support of the battalionrsquos construction effort This shop conducts Preventive Corrective and IEM per NAVSEAINST 47908B on all Heavy Shop CESE assigned to IEM This shop also maintains repair parts for assigned CESE

bull The Support Shops are normally comprised of the 5000 Shop (EC 5000-5999) Steel Shop MR Shop Tire Shop and Paint Shop These shops are specialty shops that are tasked with supporting the other shops with their particular expertise These shops also maintain repair parts for assigned CESE

bull The Crane Shop is responsible for the planned maintenance and corrective repair of all cranes and ensuring all maintenance guidelines are adhered to per NAVFAC P-307

NAVEDTRA 14264A 1-4

NOTE

At no time will cranes be put in IEM Status I

All cranes will be kept alive and cycled per COMFIRSTNCDINST 112002 Cranes on deadline are maintained in IEM Status II until removed from deadline

The following personnel organization is based on a typical Naval Mobile Construction Battalion operation but the functions are applicable to small shops where one person may perform several functions

111 Maintenance SupervisorDivision Maintenance Chief

The Maintenance SupervisorDivision Maintenance Chief (A4) is usually the senior mechanic assigned to an activity normally a Construction Mechanic Senior Chief (CMCS) who has successfully completed the Shiprsquos Maintenance and Material Management (3-M) Personnel Qualifications Standards (PQS) up to Section 304 The A4 is tasked with ensuring proper 3-M maintenance and repair of all automotive construction and material and weight handling equipment assigned to the NMCBUnit Duties and responsibilities are described in COMFIRSTNCDINST 112002 and Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B

112 Work Center Supervisor

The Work Center Supervisor (WCS) functions under the supervision of the Maintenance SupervisorDivision Maintenance Chief The Supervisor is normally a Construction Mechanic Chief (CMC) who has successfully completed 3-M PQS up to Section 303 The WCS has all the administrative and military duties of a Platoon Commander in addition to the assigned functional responsibilities and Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B

The WCS uses SKED every week to develop the assigned shoprsquos Weekly 13 Week Accountability Log The A4Division Maintenance Chief and WCS ensures that project critical equipment has priority in the shop Responsibilities of the WCS are detailed in COMFIRSTNCDINST 112002

1121 Light Shop Work Center Supervisor

The Light Shop WCS is responsible to the Maintenance SupervisorDivision Maintenance Chief for scheduled Preventive Corrective and IEM maintenance requirements for over the road material handling equipment (MHE) and personnel carrying CESE

1122 Heavy Shop Work Center Supervisor

The Heavy Shop WCS is responsible to the Maintenance SupervisorDivision Maintenance Chief for scheduled Preventive Corrective IEM and field service maintenance on ALL CONSTRUCTION CESE

NAVEDTRA 14264A 1-5

1123 Crane Crew Work Center Supervisor

The Crane Crew WCS ensures that preventive and corrective maintenance are performed on all cranes assigned All scheduled preventive maintenance is performed as per Maintenance Requirement Card (MRC)

1124 Support Shop Work Center Supervisor

The Support Shop WCS is responsible to the Maintenance Supervisor for the maintenance and repair of CESE starting with an Equipment Code (EC) of ldquo5rdquo andor as directed by the Maintenance Supervisor The WCS identifies and coordinates all maintenance requirements through the shop that necessitate the CMEOCESWHTMR skill for completion with Dispatcher on Project and ldquoCrdquo assigned CESE Responsibilities of the various shops are detailed in COMFIRSTNCDINST 112002 and include the following shops

bull Machine Shop

bull Steel and Radiator Shop

bull Electrical Shop

bull Battery Shop

bull Paint Shop

bull Tire Shop

113 Inspector

Work Center Inspectors examine the equipment for additional required repairs when the CESE is scheduled for planned or corrective maintenance Inspectors work directly for and are responsible to the Maintenance SupervisorDivision Maintenance Chief They should be senior mechanics knowledgeable and proficient in their rating and should be able to clearly describe each repair action on the MRC Each piece of equipment is inspected after repairs are completed on the 2-Kilo by each work center Inspector to ensure that work is correctly completed

Thorough final inspection increases reliability and in turn reduces the mechanics workload Inspectors may perform minor repair work that pertains to inspection procedures only Inspectors should immediately notify the Maintenance Supervisor when suspected equipment abuse or recurring failures are discovered The inspector reviews technical manuals technical bulletins maintenance bulletins Advanced Change Notices (ACNs) and Feedback Report replies Inspectors ensure required annual safety inspections and hourlymileage repairsadjustments are completed in accordance with MRCs The Inspector ensures all collateral equipment is inspected for completeness deterioration preservation shelf life and proper stowage

114 Technical Librarian

The Technical Librarian is responsible to the Maintenance Supervisor for the pre-packed library which contains operational maintenance and parts manuals The Librarian establishes and enforces checkout procedures for all manuals and maintains all required reference materials needed to research and initiate part requisitions on Naval Supply (NAVSUP) Form 1250-2s The Technical Librarian normally researches NAVEDTRA 14264A 1-6

and prepares the NAVSUP Form 1250-2s to free floor mechanics to perform maintenance functions

115 Work Center Supervisor (3-M)

Work Center Supervisors are qualified and designated in writing They are responsible to the Division Officer via the Group Supervisor if applicable for the effective operation of the 3-M System within their respective Work Center Work Center Supervisor responsibilities are the following

bull Maintain a detailed working knowledge of all equipment deficiencies within the Work Center The Work Center Supervisor uses the Current Shiprsquos Maintenance Plan (CSMP) as a daily working document for the scheduling of any maintenance actions not included on the Preventive Maintenance Schedule (PMS) schedules

bull Schedule weekly Work Center maintenance and supervise its proper accomplishment

bull Ensure the status of Work Center planned maintenance is correctly reflected on the PMS schedules

bull Ensure the Division Officer or Group Supervisor if applicable is advised of all 3-M System activity within the Work Center

bull Maintain an adequate supply of 3-M System materials within the Work Center

bull Ensure prompt reporting of all material deficiencies and completed maintenance actions as required

bull Ensure all 3-M System documents submitted from the Work Center are correct legible and promptly prepared and submitted

bull Ensure maximum use of PMS as an aid for training personnel in maintenance procedures for equipment within the Work Center

bull Ensure 3-M System Work Center files publications MRC decks Tag Guide Lists (TGLs) and EGLs are complete and current

bull Review MRCs and promptly submit a PMS Feedback Report (FBR) whenever maintenance requirements are not fully understood errors are believed to exist maintenance requirements appear inadequate or excessive additional coverage is needed or performance of the maintenance requirement would cause a hazardous condition to exist

bull Ensure PMS covers all equipment in the Work Center Maintain an accurate and current List of Effective Pages (LOEP) by comparing the documentation with the actual equipment configuration Submit PMS FBR when changes to the LOEP are required Submit configuration change requests when appropriate

bull Ensure programmed Periodic Maintenance Requirements (PMRs) scheduled for ships force accomplishment are completed and reported in strict accordance with the PMR if applicable

bull Ensure proper testing and inspection of work done by outside activities prior to job acceptance

NAVEDTRA 14264A 1-7

bull Ensure delivery of test and measurement equipment and other portable support equipment to testing and calibration Work Centers as indicated on scheduling reports

120 Maintenance Categories The goal of maintenance is to keep equipment in a safe and serviceable condition at all times at reasonable costs and to detect minor deficiencies before they develop into costly repairs The Maintenance System of the Naval Construction Force (NCF) is predicated on three categories or levels of maintenance and 3-M Organizational Intermediate and Depot The category of repairs performed is determined by the following

bull Nature of the repair

bull Level of repair parts support tools equipment and time available

bull Personnel capabilities

bull Tactical situation

An activitys range of repair parts support is keyed to the authorized level of maintenance

121 Organizational Maintenance

Organizational maintenance is that maintenance which is the responsibility of and performed by the operator and scheduled preventive maintenance services performed by trained personnel Organizational maintenance consists of proper equipment operation safety and serviceability inspections lubrication minor adjustments and services in accordance with the MRC Organizational maintenance is divided into operator and preventive maintenance as specified below

1211 Operator Maintenance

Each operator is required to perform work needed to maintain his or her vehicle in a clean safe and serviceable condition Operator maintenance includes the daily inspections before during and after operation It also includes periodic lubrication and adjustments These requirements are completed utilizing the pertinent MRC Operator maintenance is performed to ensure early detection of deficiencies

1212 Preventive Maintenance

Preventive maintenance is that maintenance which is scheduled for the purpose of maximizing equipment availability and minimizing repair costs Preventive maintenance consists of safety and mechanical inspections lubrication and services and adjustments beyond an operators responsibility Operators should assist with this work unless directed otherwise Maintenance support requiring more extensive services is categorized as Corrective level maintenance

122 Corrective Maintenance

Corrective maintenance is that maintenance which is the responsibility of and performed in any designated maintenance shop The extent of corrective maintenance

NAVEDTRA 14264A 1-8

encompasses the removal replacement repair alteration calibration modification and the rebuild and overhaul of individual assemblies subassemblies and components Although the rebuild and overhaul of major assemblies are included only essential repairs should be accomplished to ensure safe and serviceable equipment Equipment that requires extensive repairs or numerous assembly rebuilds will not be repaired without prior approval by higher authority Corrective maintenance requires a higher degree of skill than organizational maintenance and a larger assortment of repair parts and more precision tools and test equipment

To preclude the possibility of the installation of expensive components on equipment which may be scheduled for excess survey or overhaul field units must request authority from the respective Regimental (R43) Equipment Office representative prior to the purchase of component parts costing in excess of $1000 or a total repair cost in excess of $2500

123 Depot Maintenance

Depot maintenance is that maintenance performed on equipment that requires major overhaul or comprehensive restoration to a degree necessary to restore the entire unit to a like-new condition

130 Maintenance Scheduling

131 Scheduling and Shop Control

An effective and efficient maintenance program requires the establishment and upkeep of a preventive maintenance scheduling system and a sound shop control procedure Vehicles and equipment should be scheduled for inspection and servicing in accordance with the time mileage and operating hours prescribed in NAVFAC P-300 Management of Civil Engineering Support Equipment and the Material Maintenance Management Program (3M) As a minimum the schedule should ensure that each vehicle is inspected for safety at least every 12 months or 12000 miles whichever occurs first The schedule can be formulated as follows

1 Determine the number of service intervals per year per vehicle by determining each vehiclersquos estimated annual miles and then dividing by the manufacturerrsquos recommended service interval

2 Develop the number of working days between each inspection (designated inspection group) for each vehicle by dividing the number of working days per year (250) by the number of service intervals per year

3 Establish a schedule from this determination that provides a quota of vehicles for inspection daily and a balanced shop workload

Use an electronic record to track service intervals and service performed The record should include the following

bull USN

bull EC

bull Make

bull Model NAVEDTRA 14264A 1-9

bull Year

bull Estimated annual mileshours

bull Type of service

bull Date

bull Cumulative mileage or hours

bull Miles or hours of operation

bull Miles or hours operated or a specified interval

132 Shop Workload

The best method for accomplishing positive direction of shop workload is to identify and keep the following information current

bull Available work force by work center

bull Vehiclesequipment awaiting input by work center

bull Vehiclesequipment in process by work center

bull Vehiclesequipment deadlined for parts cannibalization is not a normal acceptable business practice replacement parts whether new rebuilt or refurbished or reconditioned will equal or exceed OEM standards

bull Vehiclesequipment awaiting outgoing inspection

bull Vehiclesequipment awaiting customer pickup

bull Work performed by outside contractor

133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures

Figure 1-1 illustrates recommended SRO flow procedures See NAVFAC P-300 Management of Civil Engineering Support Equipment for details on preparing SROs

NAVEDTRA 14264A 1-10

Customer brings vehicle

Customer completes hard card noting deficiencies

Will work exceed

3 hours

SRO prepared

Work performed

by in-house shop

SRO amp vehicle assigned to technician

Work accomplished

Work inspected

Other shop within

activity

CommercialContractor

OtherGovernment

Agency

Refer to P-300 4-195J

Refer to P-300 4-195H

Refer to P-300 4-195I

Is equipmentOwned byAnother Activity

Copies of SRO properly routed

Vehicle returned to customer

Refer to P-300

4-195G

Work assigned to technician

Work accomplished

Work inspected

SRO Process

Yes

No

No

No

No No No

Yes

Yes

YesYesYes

Figure 1-1 - Flow chart for Shop Repair Orders

134 Supply Support

For a maintenance organization to perform effectively it must receive responsive repair parts support This support requires a high degree of cooperation and communication between the management and staff of the shop and the shop store and between the Public Works Officer and the Supply Officer

The responsibilities involved must be understood and fulfilled Commander Naval Facilities Engineering Command (COMNAVFACENGCOM) and Commander Naval Supply Systems Command (COMNAVSUPSYSCOM) have recognized these understandings and promulgated them as policy outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment

1341 Public Works Responsibility to the Supply Department

bull Ensure that all initial support repair parts received in Public Works are turned over to the Supply Department for inventory control and accountability Initial support repair parts intended for activity stock should not be retained in the

NAVEDTRA 14264A 1-11

physical custody or records of the Supply Department once issued to the end user

bull Provide information regarding repair parts requirements needed to support vehiclesequipment on hand or for any new vehicleequipment received (Requirements would normally be generated from actual operational experience or through normal routine inspection of equipment)

bull Furnish advance information regarding repair parts requirements for scheduled overhauls (Requirements would be generated in the same manner outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment)

bull Provide technical assistance to the Transportation Shop store in identifying parts and insurance items and in determining parts interchangeability

bull Advise shop store of equipment scheduled for disposal or phase out and assist in identifying stocked items which should be eliminated from the shop store

bull In the absence of stock items provide end use Operation and Maintenance Navy (OampM N) funds to permit procurement and delivery of repair parts required for work in progress or for subsequent scheduled services and repair for which job orders have been issued

bull Conduct periodic follow-up of shop store parts orders (after required delivery date has passed) to ensure that appropriate action has been taken to reduce further delay

bull Encourage active coordinationcommunications between Public Works and Supply Department personnel

1342 Supply Department Responsibility to Public Works (Transportation)

bull Provide for the timeliest method of repair parts support through the use of available stock system stocks or purchase action using imprest fund or blanket purchase authority and indefinite delivery parts contracts (IDTC) when practical

bull Perform technical research for parts identification and to determine part numbers interchangeability and cross-referenced parts numbers

bull Collaborate with Public Works in establishing stock levels in support of current and projected vehicleequipment inventories

bull Record parts usage data for subsequent stock range and depth adjustments

bull Expedite local procurement action for immediate issue requirements when parts required are not readily available in the shop store or main supply department

bull Review outstanding requisitions regularly to ensure that status received indicates satisfactory supply action is in progress Follow up as necessary to obtain delivery status

bull Advise Public Works personnel promptly indicating delivery date(s) of requested repair parts

NAVEDTRA 14264A 1-12

bull Assume responsibility for staging of material by segregating material receipts applicable to specific repair jobs and advising the shop maintenance supervisor of material status

bull Encourage active coordinationcommunications between Supply Department and Public Works personnel

1343 Technical Parts Ordering Data

Surveys conducted by COMNAVFACENGCOM into the breakdown of repair parts support have revealed that much delay and downtime are caused by the mechanics failure to provide adequate technical data when requesting parts It should be standard practice in all maintenance shops to provide shop stores with the following information for all but common hardware and bulk material

bull Description of Major Unit Describe the vehicle or equipment unit for which the part is applicable such as Truck l2 ton 4 x 2 5000GVW

bull Manufacturer of Major Unit Give the make

bull Model of Major Unit Give manufacturers model designation

bull Year of Manufacture or Model Year Determine from nameplate

bull Vehicle Identification Number (VIN) Determine from nameplate

bull Description of Component Describe major component for which the part is required For example Engine V8 260 cubic inches Transmission Automatic 5 speed Allison Model AT-545 Component identification can be determined from manufacturers component line set lists provided with all new equipment (Manufacturers line set lists should be filed in the equipment history record jacket)

bull Manufacturer of Component Give make of major component when other than make of major unit

bull Serial Number of Component Give serial number from component nameplate where applicable

bull Description of Part Give full description of part using standard nomenclature with noun name first followed by descriptive modifiers such as sprocket camshaft kit carburetor Provide the part name when available however the correct part name is the responsibility of the parts person and should be verified Part numbers should be recorded on the SRO for future reference This practice saves research time for the parts person

135 Maintenance Forms

Proper use of appropriate forms is important to keep equipment maintained

1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)

The Operators Inspection Guide and Trouble Report is used by operators of motor vehicles to indicate the items they are required to inspect before and after operation It also serves as a means of transmitting information regarding deficiencies detected

NAVEDTRA 14264A 1-13

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

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NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  1. returnTxt1CMB01PG3 Remediation Page Click anywhere on this page to return
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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100 MAINTENANCE ADMINISTRATION Administrative guidelines concerning Civil Engineering Support Equipment (CESE) maintenance are contained in Naval Facilities Publication 300 (NAVFAC P-300) Management of Civil Engineering Support Equipment and the most current version of Commander First Naval Construction Division 112002 (COMFIRSTNCDINST 112002)

110 Maintenance Organization The organization of equipment maintenance work centers varies in the following aspects

bull Number and types of assigned equipment

bull Number and experience of personnel

bull Work hours

bull Number of shifts

bull Environmental conditions

bull Mission of the activity The typical Naval Mobile Construction Battalionrsquos (NMCBrsquos) maintenance organization is divided into several shops

bull The Light Shop is responsible for the planned maintenance and breakdown repair of all equipment assigned by the Maintenance Supervisor (generally all equipment codes beginning with 0) The number of crews is dictated by manpower and equipment quantity assigned This shop conducts Preventive Corrective and Inactive Equipment Maintenance (IEM) per Naval Sea Systems Command Instruction 47908B (NAVSEAINST 47908B) on all Light Shop CESE assigned to IEM This shop also maintains repair parts for assigned CESE

bull The Heavy Shop is responsible for the planned maintenance and breakdown repair of all equipment assigned by the Maintenance Supervisor (generally all non-light shop equipment minus the 5000 shop equipment) The priority of this shop is generally in support of the battalionrsquos construction effort This shop conducts Preventive Corrective and IEM per NAVSEAINST 47908B on all Heavy Shop CESE assigned to IEM This shop also maintains repair parts for assigned CESE

bull The Support Shops are normally comprised of the 5000 Shop (EC 5000-5999) Steel Shop MR Shop Tire Shop and Paint Shop These shops are specialty shops that are tasked with supporting the other shops with their particular expertise These shops also maintain repair parts for assigned CESE

bull The Crane Shop is responsible for the planned maintenance and corrective repair of all cranes and ensuring all maintenance guidelines are adhered to per NAVFAC P-307

NAVEDTRA 14264A 1-4

NOTE

At no time will cranes be put in IEM Status I

All cranes will be kept alive and cycled per COMFIRSTNCDINST 112002 Cranes on deadline are maintained in IEM Status II until removed from deadline

The following personnel organization is based on a typical Naval Mobile Construction Battalion operation but the functions are applicable to small shops where one person may perform several functions

111 Maintenance SupervisorDivision Maintenance Chief

The Maintenance SupervisorDivision Maintenance Chief (A4) is usually the senior mechanic assigned to an activity normally a Construction Mechanic Senior Chief (CMCS) who has successfully completed the Shiprsquos Maintenance and Material Management (3-M) Personnel Qualifications Standards (PQS) up to Section 304 The A4 is tasked with ensuring proper 3-M maintenance and repair of all automotive construction and material and weight handling equipment assigned to the NMCBUnit Duties and responsibilities are described in COMFIRSTNCDINST 112002 and Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B

112 Work Center Supervisor

The Work Center Supervisor (WCS) functions under the supervision of the Maintenance SupervisorDivision Maintenance Chief The Supervisor is normally a Construction Mechanic Chief (CMC) who has successfully completed 3-M PQS up to Section 303 The WCS has all the administrative and military duties of a Platoon Commander in addition to the assigned functional responsibilities and Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B

The WCS uses SKED every week to develop the assigned shoprsquos Weekly 13 Week Accountability Log The A4Division Maintenance Chief and WCS ensures that project critical equipment has priority in the shop Responsibilities of the WCS are detailed in COMFIRSTNCDINST 112002

1121 Light Shop Work Center Supervisor

The Light Shop WCS is responsible to the Maintenance SupervisorDivision Maintenance Chief for scheduled Preventive Corrective and IEM maintenance requirements for over the road material handling equipment (MHE) and personnel carrying CESE

1122 Heavy Shop Work Center Supervisor

The Heavy Shop WCS is responsible to the Maintenance SupervisorDivision Maintenance Chief for scheduled Preventive Corrective IEM and field service maintenance on ALL CONSTRUCTION CESE

NAVEDTRA 14264A 1-5

1123 Crane Crew Work Center Supervisor

The Crane Crew WCS ensures that preventive and corrective maintenance are performed on all cranes assigned All scheduled preventive maintenance is performed as per Maintenance Requirement Card (MRC)

1124 Support Shop Work Center Supervisor

The Support Shop WCS is responsible to the Maintenance Supervisor for the maintenance and repair of CESE starting with an Equipment Code (EC) of ldquo5rdquo andor as directed by the Maintenance Supervisor The WCS identifies and coordinates all maintenance requirements through the shop that necessitate the CMEOCESWHTMR skill for completion with Dispatcher on Project and ldquoCrdquo assigned CESE Responsibilities of the various shops are detailed in COMFIRSTNCDINST 112002 and include the following shops

bull Machine Shop

bull Steel and Radiator Shop

bull Electrical Shop

bull Battery Shop

bull Paint Shop

bull Tire Shop

113 Inspector

Work Center Inspectors examine the equipment for additional required repairs when the CESE is scheduled for planned or corrective maintenance Inspectors work directly for and are responsible to the Maintenance SupervisorDivision Maintenance Chief They should be senior mechanics knowledgeable and proficient in their rating and should be able to clearly describe each repair action on the MRC Each piece of equipment is inspected after repairs are completed on the 2-Kilo by each work center Inspector to ensure that work is correctly completed

Thorough final inspection increases reliability and in turn reduces the mechanics workload Inspectors may perform minor repair work that pertains to inspection procedures only Inspectors should immediately notify the Maintenance Supervisor when suspected equipment abuse or recurring failures are discovered The inspector reviews technical manuals technical bulletins maintenance bulletins Advanced Change Notices (ACNs) and Feedback Report replies Inspectors ensure required annual safety inspections and hourlymileage repairsadjustments are completed in accordance with MRCs The Inspector ensures all collateral equipment is inspected for completeness deterioration preservation shelf life and proper stowage

114 Technical Librarian

The Technical Librarian is responsible to the Maintenance Supervisor for the pre-packed library which contains operational maintenance and parts manuals The Librarian establishes and enforces checkout procedures for all manuals and maintains all required reference materials needed to research and initiate part requisitions on Naval Supply (NAVSUP) Form 1250-2s The Technical Librarian normally researches NAVEDTRA 14264A 1-6

and prepares the NAVSUP Form 1250-2s to free floor mechanics to perform maintenance functions

115 Work Center Supervisor (3-M)

Work Center Supervisors are qualified and designated in writing They are responsible to the Division Officer via the Group Supervisor if applicable for the effective operation of the 3-M System within their respective Work Center Work Center Supervisor responsibilities are the following

bull Maintain a detailed working knowledge of all equipment deficiencies within the Work Center The Work Center Supervisor uses the Current Shiprsquos Maintenance Plan (CSMP) as a daily working document for the scheduling of any maintenance actions not included on the Preventive Maintenance Schedule (PMS) schedules

bull Schedule weekly Work Center maintenance and supervise its proper accomplishment

bull Ensure the status of Work Center planned maintenance is correctly reflected on the PMS schedules

bull Ensure the Division Officer or Group Supervisor if applicable is advised of all 3-M System activity within the Work Center

bull Maintain an adequate supply of 3-M System materials within the Work Center

bull Ensure prompt reporting of all material deficiencies and completed maintenance actions as required

bull Ensure all 3-M System documents submitted from the Work Center are correct legible and promptly prepared and submitted

bull Ensure maximum use of PMS as an aid for training personnel in maintenance procedures for equipment within the Work Center

bull Ensure 3-M System Work Center files publications MRC decks Tag Guide Lists (TGLs) and EGLs are complete and current

bull Review MRCs and promptly submit a PMS Feedback Report (FBR) whenever maintenance requirements are not fully understood errors are believed to exist maintenance requirements appear inadequate or excessive additional coverage is needed or performance of the maintenance requirement would cause a hazardous condition to exist

bull Ensure PMS covers all equipment in the Work Center Maintain an accurate and current List of Effective Pages (LOEP) by comparing the documentation with the actual equipment configuration Submit PMS FBR when changes to the LOEP are required Submit configuration change requests when appropriate

bull Ensure programmed Periodic Maintenance Requirements (PMRs) scheduled for ships force accomplishment are completed and reported in strict accordance with the PMR if applicable

bull Ensure proper testing and inspection of work done by outside activities prior to job acceptance

NAVEDTRA 14264A 1-7

bull Ensure delivery of test and measurement equipment and other portable support equipment to testing and calibration Work Centers as indicated on scheduling reports

120 Maintenance Categories The goal of maintenance is to keep equipment in a safe and serviceable condition at all times at reasonable costs and to detect minor deficiencies before they develop into costly repairs The Maintenance System of the Naval Construction Force (NCF) is predicated on three categories or levels of maintenance and 3-M Organizational Intermediate and Depot The category of repairs performed is determined by the following

bull Nature of the repair

bull Level of repair parts support tools equipment and time available

bull Personnel capabilities

bull Tactical situation

An activitys range of repair parts support is keyed to the authorized level of maintenance

121 Organizational Maintenance

Organizational maintenance is that maintenance which is the responsibility of and performed by the operator and scheduled preventive maintenance services performed by trained personnel Organizational maintenance consists of proper equipment operation safety and serviceability inspections lubrication minor adjustments and services in accordance with the MRC Organizational maintenance is divided into operator and preventive maintenance as specified below

1211 Operator Maintenance

Each operator is required to perform work needed to maintain his or her vehicle in a clean safe and serviceable condition Operator maintenance includes the daily inspections before during and after operation It also includes periodic lubrication and adjustments These requirements are completed utilizing the pertinent MRC Operator maintenance is performed to ensure early detection of deficiencies

1212 Preventive Maintenance

Preventive maintenance is that maintenance which is scheduled for the purpose of maximizing equipment availability and minimizing repair costs Preventive maintenance consists of safety and mechanical inspections lubrication and services and adjustments beyond an operators responsibility Operators should assist with this work unless directed otherwise Maintenance support requiring more extensive services is categorized as Corrective level maintenance

122 Corrective Maintenance

Corrective maintenance is that maintenance which is the responsibility of and performed in any designated maintenance shop The extent of corrective maintenance

NAVEDTRA 14264A 1-8

encompasses the removal replacement repair alteration calibration modification and the rebuild and overhaul of individual assemblies subassemblies and components Although the rebuild and overhaul of major assemblies are included only essential repairs should be accomplished to ensure safe and serviceable equipment Equipment that requires extensive repairs or numerous assembly rebuilds will not be repaired without prior approval by higher authority Corrective maintenance requires a higher degree of skill than organizational maintenance and a larger assortment of repair parts and more precision tools and test equipment

To preclude the possibility of the installation of expensive components on equipment which may be scheduled for excess survey or overhaul field units must request authority from the respective Regimental (R43) Equipment Office representative prior to the purchase of component parts costing in excess of $1000 or a total repair cost in excess of $2500

123 Depot Maintenance

Depot maintenance is that maintenance performed on equipment that requires major overhaul or comprehensive restoration to a degree necessary to restore the entire unit to a like-new condition

130 Maintenance Scheduling

131 Scheduling and Shop Control

An effective and efficient maintenance program requires the establishment and upkeep of a preventive maintenance scheduling system and a sound shop control procedure Vehicles and equipment should be scheduled for inspection and servicing in accordance with the time mileage and operating hours prescribed in NAVFAC P-300 Management of Civil Engineering Support Equipment and the Material Maintenance Management Program (3M) As a minimum the schedule should ensure that each vehicle is inspected for safety at least every 12 months or 12000 miles whichever occurs first The schedule can be formulated as follows

1 Determine the number of service intervals per year per vehicle by determining each vehiclersquos estimated annual miles and then dividing by the manufacturerrsquos recommended service interval

2 Develop the number of working days between each inspection (designated inspection group) for each vehicle by dividing the number of working days per year (250) by the number of service intervals per year

3 Establish a schedule from this determination that provides a quota of vehicles for inspection daily and a balanced shop workload

Use an electronic record to track service intervals and service performed The record should include the following

bull USN

bull EC

bull Make

bull Model NAVEDTRA 14264A 1-9

bull Year

bull Estimated annual mileshours

bull Type of service

bull Date

bull Cumulative mileage or hours

bull Miles or hours of operation

bull Miles or hours operated or a specified interval

132 Shop Workload

The best method for accomplishing positive direction of shop workload is to identify and keep the following information current

bull Available work force by work center

bull Vehiclesequipment awaiting input by work center

bull Vehiclesequipment in process by work center

bull Vehiclesequipment deadlined for parts cannibalization is not a normal acceptable business practice replacement parts whether new rebuilt or refurbished or reconditioned will equal or exceed OEM standards

bull Vehiclesequipment awaiting outgoing inspection

bull Vehiclesequipment awaiting customer pickup

bull Work performed by outside contractor

133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures

Figure 1-1 illustrates recommended SRO flow procedures See NAVFAC P-300 Management of Civil Engineering Support Equipment for details on preparing SROs

NAVEDTRA 14264A 1-10

Customer brings vehicle

Customer completes hard card noting deficiencies

Will work exceed

3 hours

SRO prepared

Work performed

by in-house shop

SRO amp vehicle assigned to technician

Work accomplished

Work inspected

Other shop within

activity

CommercialContractor

OtherGovernment

Agency

Refer to P-300 4-195J

Refer to P-300 4-195H

Refer to P-300 4-195I

Is equipmentOwned byAnother Activity

Copies of SRO properly routed

Vehicle returned to customer

Refer to P-300

4-195G

Work assigned to technician

Work accomplished

Work inspected

SRO Process

Yes

No

No

No

No No No

Yes

Yes

YesYesYes

Figure 1-1 - Flow chart for Shop Repair Orders

134 Supply Support

For a maintenance organization to perform effectively it must receive responsive repair parts support This support requires a high degree of cooperation and communication between the management and staff of the shop and the shop store and between the Public Works Officer and the Supply Officer

The responsibilities involved must be understood and fulfilled Commander Naval Facilities Engineering Command (COMNAVFACENGCOM) and Commander Naval Supply Systems Command (COMNAVSUPSYSCOM) have recognized these understandings and promulgated them as policy outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment

1341 Public Works Responsibility to the Supply Department

bull Ensure that all initial support repair parts received in Public Works are turned over to the Supply Department for inventory control and accountability Initial support repair parts intended for activity stock should not be retained in the

NAVEDTRA 14264A 1-11

physical custody or records of the Supply Department once issued to the end user

bull Provide information regarding repair parts requirements needed to support vehiclesequipment on hand or for any new vehicleequipment received (Requirements would normally be generated from actual operational experience or through normal routine inspection of equipment)

bull Furnish advance information regarding repair parts requirements for scheduled overhauls (Requirements would be generated in the same manner outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment)

bull Provide technical assistance to the Transportation Shop store in identifying parts and insurance items and in determining parts interchangeability

bull Advise shop store of equipment scheduled for disposal or phase out and assist in identifying stocked items which should be eliminated from the shop store

bull In the absence of stock items provide end use Operation and Maintenance Navy (OampM N) funds to permit procurement and delivery of repair parts required for work in progress or for subsequent scheduled services and repair for which job orders have been issued

bull Conduct periodic follow-up of shop store parts orders (after required delivery date has passed) to ensure that appropriate action has been taken to reduce further delay

bull Encourage active coordinationcommunications between Public Works and Supply Department personnel

1342 Supply Department Responsibility to Public Works (Transportation)

bull Provide for the timeliest method of repair parts support through the use of available stock system stocks or purchase action using imprest fund or blanket purchase authority and indefinite delivery parts contracts (IDTC) when practical

bull Perform technical research for parts identification and to determine part numbers interchangeability and cross-referenced parts numbers

bull Collaborate with Public Works in establishing stock levels in support of current and projected vehicleequipment inventories

bull Record parts usage data for subsequent stock range and depth adjustments

bull Expedite local procurement action for immediate issue requirements when parts required are not readily available in the shop store or main supply department

bull Review outstanding requisitions regularly to ensure that status received indicates satisfactory supply action is in progress Follow up as necessary to obtain delivery status

bull Advise Public Works personnel promptly indicating delivery date(s) of requested repair parts

NAVEDTRA 14264A 1-12

bull Assume responsibility for staging of material by segregating material receipts applicable to specific repair jobs and advising the shop maintenance supervisor of material status

bull Encourage active coordinationcommunications between Supply Department and Public Works personnel

1343 Technical Parts Ordering Data

Surveys conducted by COMNAVFACENGCOM into the breakdown of repair parts support have revealed that much delay and downtime are caused by the mechanics failure to provide adequate technical data when requesting parts It should be standard practice in all maintenance shops to provide shop stores with the following information for all but common hardware and bulk material

bull Description of Major Unit Describe the vehicle or equipment unit for which the part is applicable such as Truck l2 ton 4 x 2 5000GVW

bull Manufacturer of Major Unit Give the make

bull Model of Major Unit Give manufacturers model designation

bull Year of Manufacture or Model Year Determine from nameplate

bull Vehicle Identification Number (VIN) Determine from nameplate

bull Description of Component Describe major component for which the part is required For example Engine V8 260 cubic inches Transmission Automatic 5 speed Allison Model AT-545 Component identification can be determined from manufacturers component line set lists provided with all new equipment (Manufacturers line set lists should be filed in the equipment history record jacket)

bull Manufacturer of Component Give make of major component when other than make of major unit

bull Serial Number of Component Give serial number from component nameplate where applicable

bull Description of Part Give full description of part using standard nomenclature with noun name first followed by descriptive modifiers such as sprocket camshaft kit carburetor Provide the part name when available however the correct part name is the responsibility of the parts person and should be verified Part numbers should be recorded on the SRO for future reference This practice saves research time for the parts person

135 Maintenance Forms

Proper use of appropriate forms is important to keep equipment maintained

1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)

The Operators Inspection Guide and Trouble Report is used by operators of motor vehicles to indicate the items they are required to inspect before and after operation It also serves as a means of transmitting information regarding deficiencies detected

NAVEDTRA 14264A 1-13

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

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(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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NOTE

At no time will cranes be put in IEM Status I

All cranes will be kept alive and cycled per COMFIRSTNCDINST 112002 Cranes on deadline are maintained in IEM Status II until removed from deadline

The following personnel organization is based on a typical Naval Mobile Construction Battalion operation but the functions are applicable to small shops where one person may perform several functions

111 Maintenance SupervisorDivision Maintenance Chief

The Maintenance SupervisorDivision Maintenance Chief (A4) is usually the senior mechanic assigned to an activity normally a Construction Mechanic Senior Chief (CMCS) who has successfully completed the Shiprsquos Maintenance and Material Management (3-M) Personnel Qualifications Standards (PQS) up to Section 304 The A4 is tasked with ensuring proper 3-M maintenance and repair of all automotive construction and material and weight handling equipment assigned to the NMCBUnit Duties and responsibilities are described in COMFIRSTNCDINST 112002 and Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B

112 Work Center Supervisor

The Work Center Supervisor (WCS) functions under the supervision of the Maintenance SupervisorDivision Maintenance Chief The Supervisor is normally a Construction Mechanic Chief (CMC) who has successfully completed 3-M PQS up to Section 303 The WCS has all the administrative and military duties of a Platoon Commander in addition to the assigned functional responsibilities and Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B

The WCS uses SKED every week to develop the assigned shoprsquos Weekly 13 Week Accountability Log The A4Division Maintenance Chief and WCS ensures that project critical equipment has priority in the shop Responsibilities of the WCS are detailed in COMFIRSTNCDINST 112002

1121 Light Shop Work Center Supervisor

The Light Shop WCS is responsible to the Maintenance SupervisorDivision Maintenance Chief for scheduled Preventive Corrective and IEM maintenance requirements for over the road material handling equipment (MHE) and personnel carrying CESE

1122 Heavy Shop Work Center Supervisor

The Heavy Shop WCS is responsible to the Maintenance SupervisorDivision Maintenance Chief for scheduled Preventive Corrective IEM and field service maintenance on ALL CONSTRUCTION CESE

NAVEDTRA 14264A 1-5

1123 Crane Crew Work Center Supervisor

The Crane Crew WCS ensures that preventive and corrective maintenance are performed on all cranes assigned All scheduled preventive maintenance is performed as per Maintenance Requirement Card (MRC)

1124 Support Shop Work Center Supervisor

The Support Shop WCS is responsible to the Maintenance Supervisor for the maintenance and repair of CESE starting with an Equipment Code (EC) of ldquo5rdquo andor as directed by the Maintenance Supervisor The WCS identifies and coordinates all maintenance requirements through the shop that necessitate the CMEOCESWHTMR skill for completion with Dispatcher on Project and ldquoCrdquo assigned CESE Responsibilities of the various shops are detailed in COMFIRSTNCDINST 112002 and include the following shops

bull Machine Shop

bull Steel and Radiator Shop

bull Electrical Shop

bull Battery Shop

bull Paint Shop

bull Tire Shop

113 Inspector

Work Center Inspectors examine the equipment for additional required repairs when the CESE is scheduled for planned or corrective maintenance Inspectors work directly for and are responsible to the Maintenance SupervisorDivision Maintenance Chief They should be senior mechanics knowledgeable and proficient in their rating and should be able to clearly describe each repair action on the MRC Each piece of equipment is inspected after repairs are completed on the 2-Kilo by each work center Inspector to ensure that work is correctly completed

Thorough final inspection increases reliability and in turn reduces the mechanics workload Inspectors may perform minor repair work that pertains to inspection procedures only Inspectors should immediately notify the Maintenance Supervisor when suspected equipment abuse or recurring failures are discovered The inspector reviews technical manuals technical bulletins maintenance bulletins Advanced Change Notices (ACNs) and Feedback Report replies Inspectors ensure required annual safety inspections and hourlymileage repairsadjustments are completed in accordance with MRCs The Inspector ensures all collateral equipment is inspected for completeness deterioration preservation shelf life and proper stowage

114 Technical Librarian

The Technical Librarian is responsible to the Maintenance Supervisor for the pre-packed library which contains operational maintenance and parts manuals The Librarian establishes and enforces checkout procedures for all manuals and maintains all required reference materials needed to research and initiate part requisitions on Naval Supply (NAVSUP) Form 1250-2s The Technical Librarian normally researches NAVEDTRA 14264A 1-6

and prepares the NAVSUP Form 1250-2s to free floor mechanics to perform maintenance functions

115 Work Center Supervisor (3-M)

Work Center Supervisors are qualified and designated in writing They are responsible to the Division Officer via the Group Supervisor if applicable for the effective operation of the 3-M System within their respective Work Center Work Center Supervisor responsibilities are the following

bull Maintain a detailed working knowledge of all equipment deficiencies within the Work Center The Work Center Supervisor uses the Current Shiprsquos Maintenance Plan (CSMP) as a daily working document for the scheduling of any maintenance actions not included on the Preventive Maintenance Schedule (PMS) schedules

bull Schedule weekly Work Center maintenance and supervise its proper accomplishment

bull Ensure the status of Work Center planned maintenance is correctly reflected on the PMS schedules

bull Ensure the Division Officer or Group Supervisor if applicable is advised of all 3-M System activity within the Work Center

bull Maintain an adequate supply of 3-M System materials within the Work Center

bull Ensure prompt reporting of all material deficiencies and completed maintenance actions as required

bull Ensure all 3-M System documents submitted from the Work Center are correct legible and promptly prepared and submitted

bull Ensure maximum use of PMS as an aid for training personnel in maintenance procedures for equipment within the Work Center

bull Ensure 3-M System Work Center files publications MRC decks Tag Guide Lists (TGLs) and EGLs are complete and current

bull Review MRCs and promptly submit a PMS Feedback Report (FBR) whenever maintenance requirements are not fully understood errors are believed to exist maintenance requirements appear inadequate or excessive additional coverage is needed or performance of the maintenance requirement would cause a hazardous condition to exist

bull Ensure PMS covers all equipment in the Work Center Maintain an accurate and current List of Effective Pages (LOEP) by comparing the documentation with the actual equipment configuration Submit PMS FBR when changes to the LOEP are required Submit configuration change requests when appropriate

bull Ensure programmed Periodic Maintenance Requirements (PMRs) scheduled for ships force accomplishment are completed and reported in strict accordance with the PMR if applicable

bull Ensure proper testing and inspection of work done by outside activities prior to job acceptance

NAVEDTRA 14264A 1-7

bull Ensure delivery of test and measurement equipment and other portable support equipment to testing and calibration Work Centers as indicated on scheduling reports

120 Maintenance Categories The goal of maintenance is to keep equipment in a safe and serviceable condition at all times at reasonable costs and to detect minor deficiencies before they develop into costly repairs The Maintenance System of the Naval Construction Force (NCF) is predicated on three categories or levels of maintenance and 3-M Organizational Intermediate and Depot The category of repairs performed is determined by the following

bull Nature of the repair

bull Level of repair parts support tools equipment and time available

bull Personnel capabilities

bull Tactical situation

An activitys range of repair parts support is keyed to the authorized level of maintenance

121 Organizational Maintenance

Organizational maintenance is that maintenance which is the responsibility of and performed by the operator and scheduled preventive maintenance services performed by trained personnel Organizational maintenance consists of proper equipment operation safety and serviceability inspections lubrication minor adjustments and services in accordance with the MRC Organizational maintenance is divided into operator and preventive maintenance as specified below

1211 Operator Maintenance

Each operator is required to perform work needed to maintain his or her vehicle in a clean safe and serviceable condition Operator maintenance includes the daily inspections before during and after operation It also includes periodic lubrication and adjustments These requirements are completed utilizing the pertinent MRC Operator maintenance is performed to ensure early detection of deficiencies

1212 Preventive Maintenance

Preventive maintenance is that maintenance which is scheduled for the purpose of maximizing equipment availability and minimizing repair costs Preventive maintenance consists of safety and mechanical inspections lubrication and services and adjustments beyond an operators responsibility Operators should assist with this work unless directed otherwise Maintenance support requiring more extensive services is categorized as Corrective level maintenance

122 Corrective Maintenance

Corrective maintenance is that maintenance which is the responsibility of and performed in any designated maintenance shop The extent of corrective maintenance

NAVEDTRA 14264A 1-8

encompasses the removal replacement repair alteration calibration modification and the rebuild and overhaul of individual assemblies subassemblies and components Although the rebuild and overhaul of major assemblies are included only essential repairs should be accomplished to ensure safe and serviceable equipment Equipment that requires extensive repairs or numerous assembly rebuilds will not be repaired without prior approval by higher authority Corrective maintenance requires a higher degree of skill than organizational maintenance and a larger assortment of repair parts and more precision tools and test equipment

To preclude the possibility of the installation of expensive components on equipment which may be scheduled for excess survey or overhaul field units must request authority from the respective Regimental (R43) Equipment Office representative prior to the purchase of component parts costing in excess of $1000 or a total repair cost in excess of $2500

123 Depot Maintenance

Depot maintenance is that maintenance performed on equipment that requires major overhaul or comprehensive restoration to a degree necessary to restore the entire unit to a like-new condition

130 Maintenance Scheduling

131 Scheduling and Shop Control

An effective and efficient maintenance program requires the establishment and upkeep of a preventive maintenance scheduling system and a sound shop control procedure Vehicles and equipment should be scheduled for inspection and servicing in accordance with the time mileage and operating hours prescribed in NAVFAC P-300 Management of Civil Engineering Support Equipment and the Material Maintenance Management Program (3M) As a minimum the schedule should ensure that each vehicle is inspected for safety at least every 12 months or 12000 miles whichever occurs first The schedule can be formulated as follows

1 Determine the number of service intervals per year per vehicle by determining each vehiclersquos estimated annual miles and then dividing by the manufacturerrsquos recommended service interval

2 Develop the number of working days between each inspection (designated inspection group) for each vehicle by dividing the number of working days per year (250) by the number of service intervals per year

3 Establish a schedule from this determination that provides a quota of vehicles for inspection daily and a balanced shop workload

Use an electronic record to track service intervals and service performed The record should include the following

bull USN

bull EC

bull Make

bull Model NAVEDTRA 14264A 1-9

bull Year

bull Estimated annual mileshours

bull Type of service

bull Date

bull Cumulative mileage or hours

bull Miles or hours of operation

bull Miles or hours operated or a specified interval

132 Shop Workload

The best method for accomplishing positive direction of shop workload is to identify and keep the following information current

bull Available work force by work center

bull Vehiclesequipment awaiting input by work center

bull Vehiclesequipment in process by work center

bull Vehiclesequipment deadlined for parts cannibalization is not a normal acceptable business practice replacement parts whether new rebuilt or refurbished or reconditioned will equal or exceed OEM standards

bull Vehiclesequipment awaiting outgoing inspection

bull Vehiclesequipment awaiting customer pickup

bull Work performed by outside contractor

133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures

Figure 1-1 illustrates recommended SRO flow procedures See NAVFAC P-300 Management of Civil Engineering Support Equipment for details on preparing SROs

NAVEDTRA 14264A 1-10

Customer brings vehicle

Customer completes hard card noting deficiencies

Will work exceed

3 hours

SRO prepared

Work performed

by in-house shop

SRO amp vehicle assigned to technician

Work accomplished

Work inspected

Other shop within

activity

CommercialContractor

OtherGovernment

Agency

Refer to P-300 4-195J

Refer to P-300 4-195H

Refer to P-300 4-195I

Is equipmentOwned byAnother Activity

Copies of SRO properly routed

Vehicle returned to customer

Refer to P-300

4-195G

Work assigned to technician

Work accomplished

Work inspected

SRO Process

Yes

No

No

No

No No No

Yes

Yes

YesYesYes

Figure 1-1 - Flow chart for Shop Repair Orders

134 Supply Support

For a maintenance organization to perform effectively it must receive responsive repair parts support This support requires a high degree of cooperation and communication between the management and staff of the shop and the shop store and between the Public Works Officer and the Supply Officer

The responsibilities involved must be understood and fulfilled Commander Naval Facilities Engineering Command (COMNAVFACENGCOM) and Commander Naval Supply Systems Command (COMNAVSUPSYSCOM) have recognized these understandings and promulgated them as policy outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment

1341 Public Works Responsibility to the Supply Department

bull Ensure that all initial support repair parts received in Public Works are turned over to the Supply Department for inventory control and accountability Initial support repair parts intended for activity stock should not be retained in the

NAVEDTRA 14264A 1-11

physical custody or records of the Supply Department once issued to the end user

bull Provide information regarding repair parts requirements needed to support vehiclesequipment on hand or for any new vehicleequipment received (Requirements would normally be generated from actual operational experience or through normal routine inspection of equipment)

bull Furnish advance information regarding repair parts requirements for scheduled overhauls (Requirements would be generated in the same manner outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment)

bull Provide technical assistance to the Transportation Shop store in identifying parts and insurance items and in determining parts interchangeability

bull Advise shop store of equipment scheduled for disposal or phase out and assist in identifying stocked items which should be eliminated from the shop store

bull In the absence of stock items provide end use Operation and Maintenance Navy (OampM N) funds to permit procurement and delivery of repair parts required for work in progress or for subsequent scheduled services and repair for which job orders have been issued

bull Conduct periodic follow-up of shop store parts orders (after required delivery date has passed) to ensure that appropriate action has been taken to reduce further delay

bull Encourage active coordinationcommunications between Public Works and Supply Department personnel

1342 Supply Department Responsibility to Public Works (Transportation)

bull Provide for the timeliest method of repair parts support through the use of available stock system stocks or purchase action using imprest fund or blanket purchase authority and indefinite delivery parts contracts (IDTC) when practical

bull Perform technical research for parts identification and to determine part numbers interchangeability and cross-referenced parts numbers

bull Collaborate with Public Works in establishing stock levels in support of current and projected vehicleequipment inventories

bull Record parts usage data for subsequent stock range and depth adjustments

bull Expedite local procurement action for immediate issue requirements when parts required are not readily available in the shop store or main supply department

bull Review outstanding requisitions regularly to ensure that status received indicates satisfactory supply action is in progress Follow up as necessary to obtain delivery status

bull Advise Public Works personnel promptly indicating delivery date(s) of requested repair parts

NAVEDTRA 14264A 1-12

bull Assume responsibility for staging of material by segregating material receipts applicable to specific repair jobs and advising the shop maintenance supervisor of material status

bull Encourage active coordinationcommunications between Supply Department and Public Works personnel

1343 Technical Parts Ordering Data

Surveys conducted by COMNAVFACENGCOM into the breakdown of repair parts support have revealed that much delay and downtime are caused by the mechanics failure to provide adequate technical data when requesting parts It should be standard practice in all maintenance shops to provide shop stores with the following information for all but common hardware and bulk material

bull Description of Major Unit Describe the vehicle or equipment unit for which the part is applicable such as Truck l2 ton 4 x 2 5000GVW

bull Manufacturer of Major Unit Give the make

bull Model of Major Unit Give manufacturers model designation

bull Year of Manufacture or Model Year Determine from nameplate

bull Vehicle Identification Number (VIN) Determine from nameplate

bull Description of Component Describe major component for which the part is required For example Engine V8 260 cubic inches Transmission Automatic 5 speed Allison Model AT-545 Component identification can be determined from manufacturers component line set lists provided with all new equipment (Manufacturers line set lists should be filed in the equipment history record jacket)

bull Manufacturer of Component Give make of major component when other than make of major unit

bull Serial Number of Component Give serial number from component nameplate where applicable

bull Description of Part Give full description of part using standard nomenclature with noun name first followed by descriptive modifiers such as sprocket camshaft kit carburetor Provide the part name when available however the correct part name is the responsibility of the parts person and should be verified Part numbers should be recorded on the SRO for future reference This practice saves research time for the parts person

135 Maintenance Forms

Proper use of appropriate forms is important to keep equipment maintained

1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)

The Operators Inspection Guide and Trouble Report is used by operators of motor vehicles to indicate the items they are required to inspect before and after operation It also serves as a means of transmitting information regarding deficiencies detected

NAVEDTRA 14264A 1-13

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  142. txtRate
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  147. txtDescription
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

1123 Crane Crew Work Center Supervisor

The Crane Crew WCS ensures that preventive and corrective maintenance are performed on all cranes assigned All scheduled preventive maintenance is performed as per Maintenance Requirement Card (MRC)

1124 Support Shop Work Center Supervisor

The Support Shop WCS is responsible to the Maintenance Supervisor for the maintenance and repair of CESE starting with an Equipment Code (EC) of ldquo5rdquo andor as directed by the Maintenance Supervisor The WCS identifies and coordinates all maintenance requirements through the shop that necessitate the CMEOCESWHTMR skill for completion with Dispatcher on Project and ldquoCrdquo assigned CESE Responsibilities of the various shops are detailed in COMFIRSTNCDINST 112002 and include the following shops

bull Machine Shop

bull Steel and Radiator Shop

bull Electrical Shop

bull Battery Shop

bull Paint Shop

bull Tire Shop

113 Inspector

Work Center Inspectors examine the equipment for additional required repairs when the CESE is scheduled for planned or corrective maintenance Inspectors work directly for and are responsible to the Maintenance SupervisorDivision Maintenance Chief They should be senior mechanics knowledgeable and proficient in their rating and should be able to clearly describe each repair action on the MRC Each piece of equipment is inspected after repairs are completed on the 2-Kilo by each work center Inspector to ensure that work is correctly completed

Thorough final inspection increases reliability and in turn reduces the mechanics workload Inspectors may perform minor repair work that pertains to inspection procedures only Inspectors should immediately notify the Maintenance Supervisor when suspected equipment abuse or recurring failures are discovered The inspector reviews technical manuals technical bulletins maintenance bulletins Advanced Change Notices (ACNs) and Feedback Report replies Inspectors ensure required annual safety inspections and hourlymileage repairsadjustments are completed in accordance with MRCs The Inspector ensures all collateral equipment is inspected for completeness deterioration preservation shelf life and proper stowage

114 Technical Librarian

The Technical Librarian is responsible to the Maintenance Supervisor for the pre-packed library which contains operational maintenance and parts manuals The Librarian establishes and enforces checkout procedures for all manuals and maintains all required reference materials needed to research and initiate part requisitions on Naval Supply (NAVSUP) Form 1250-2s The Technical Librarian normally researches NAVEDTRA 14264A 1-6

and prepares the NAVSUP Form 1250-2s to free floor mechanics to perform maintenance functions

115 Work Center Supervisor (3-M)

Work Center Supervisors are qualified and designated in writing They are responsible to the Division Officer via the Group Supervisor if applicable for the effective operation of the 3-M System within their respective Work Center Work Center Supervisor responsibilities are the following

bull Maintain a detailed working knowledge of all equipment deficiencies within the Work Center The Work Center Supervisor uses the Current Shiprsquos Maintenance Plan (CSMP) as a daily working document for the scheduling of any maintenance actions not included on the Preventive Maintenance Schedule (PMS) schedules

bull Schedule weekly Work Center maintenance and supervise its proper accomplishment

bull Ensure the status of Work Center planned maintenance is correctly reflected on the PMS schedules

bull Ensure the Division Officer or Group Supervisor if applicable is advised of all 3-M System activity within the Work Center

bull Maintain an adequate supply of 3-M System materials within the Work Center

bull Ensure prompt reporting of all material deficiencies and completed maintenance actions as required

bull Ensure all 3-M System documents submitted from the Work Center are correct legible and promptly prepared and submitted

bull Ensure maximum use of PMS as an aid for training personnel in maintenance procedures for equipment within the Work Center

bull Ensure 3-M System Work Center files publications MRC decks Tag Guide Lists (TGLs) and EGLs are complete and current

bull Review MRCs and promptly submit a PMS Feedback Report (FBR) whenever maintenance requirements are not fully understood errors are believed to exist maintenance requirements appear inadequate or excessive additional coverage is needed or performance of the maintenance requirement would cause a hazardous condition to exist

bull Ensure PMS covers all equipment in the Work Center Maintain an accurate and current List of Effective Pages (LOEP) by comparing the documentation with the actual equipment configuration Submit PMS FBR when changes to the LOEP are required Submit configuration change requests when appropriate

bull Ensure programmed Periodic Maintenance Requirements (PMRs) scheduled for ships force accomplishment are completed and reported in strict accordance with the PMR if applicable

bull Ensure proper testing and inspection of work done by outside activities prior to job acceptance

NAVEDTRA 14264A 1-7

bull Ensure delivery of test and measurement equipment and other portable support equipment to testing and calibration Work Centers as indicated on scheduling reports

120 Maintenance Categories The goal of maintenance is to keep equipment in a safe and serviceable condition at all times at reasonable costs and to detect minor deficiencies before they develop into costly repairs The Maintenance System of the Naval Construction Force (NCF) is predicated on three categories or levels of maintenance and 3-M Organizational Intermediate and Depot The category of repairs performed is determined by the following

bull Nature of the repair

bull Level of repair parts support tools equipment and time available

bull Personnel capabilities

bull Tactical situation

An activitys range of repair parts support is keyed to the authorized level of maintenance

121 Organizational Maintenance

Organizational maintenance is that maintenance which is the responsibility of and performed by the operator and scheduled preventive maintenance services performed by trained personnel Organizational maintenance consists of proper equipment operation safety and serviceability inspections lubrication minor adjustments and services in accordance with the MRC Organizational maintenance is divided into operator and preventive maintenance as specified below

1211 Operator Maintenance

Each operator is required to perform work needed to maintain his or her vehicle in a clean safe and serviceable condition Operator maintenance includes the daily inspections before during and after operation It also includes periodic lubrication and adjustments These requirements are completed utilizing the pertinent MRC Operator maintenance is performed to ensure early detection of deficiencies

1212 Preventive Maintenance

Preventive maintenance is that maintenance which is scheduled for the purpose of maximizing equipment availability and minimizing repair costs Preventive maintenance consists of safety and mechanical inspections lubrication and services and adjustments beyond an operators responsibility Operators should assist with this work unless directed otherwise Maintenance support requiring more extensive services is categorized as Corrective level maintenance

122 Corrective Maintenance

Corrective maintenance is that maintenance which is the responsibility of and performed in any designated maintenance shop The extent of corrective maintenance

NAVEDTRA 14264A 1-8

encompasses the removal replacement repair alteration calibration modification and the rebuild and overhaul of individual assemblies subassemblies and components Although the rebuild and overhaul of major assemblies are included only essential repairs should be accomplished to ensure safe and serviceable equipment Equipment that requires extensive repairs or numerous assembly rebuilds will not be repaired without prior approval by higher authority Corrective maintenance requires a higher degree of skill than organizational maintenance and a larger assortment of repair parts and more precision tools and test equipment

To preclude the possibility of the installation of expensive components on equipment which may be scheduled for excess survey or overhaul field units must request authority from the respective Regimental (R43) Equipment Office representative prior to the purchase of component parts costing in excess of $1000 or a total repair cost in excess of $2500

123 Depot Maintenance

Depot maintenance is that maintenance performed on equipment that requires major overhaul or comprehensive restoration to a degree necessary to restore the entire unit to a like-new condition

130 Maintenance Scheduling

131 Scheduling and Shop Control

An effective and efficient maintenance program requires the establishment and upkeep of a preventive maintenance scheduling system and a sound shop control procedure Vehicles and equipment should be scheduled for inspection and servicing in accordance with the time mileage and operating hours prescribed in NAVFAC P-300 Management of Civil Engineering Support Equipment and the Material Maintenance Management Program (3M) As a minimum the schedule should ensure that each vehicle is inspected for safety at least every 12 months or 12000 miles whichever occurs first The schedule can be formulated as follows

1 Determine the number of service intervals per year per vehicle by determining each vehiclersquos estimated annual miles and then dividing by the manufacturerrsquos recommended service interval

2 Develop the number of working days between each inspection (designated inspection group) for each vehicle by dividing the number of working days per year (250) by the number of service intervals per year

3 Establish a schedule from this determination that provides a quota of vehicles for inspection daily and a balanced shop workload

Use an electronic record to track service intervals and service performed The record should include the following

bull USN

bull EC

bull Make

bull Model NAVEDTRA 14264A 1-9

bull Year

bull Estimated annual mileshours

bull Type of service

bull Date

bull Cumulative mileage or hours

bull Miles or hours of operation

bull Miles or hours operated or a specified interval

132 Shop Workload

The best method for accomplishing positive direction of shop workload is to identify and keep the following information current

bull Available work force by work center

bull Vehiclesequipment awaiting input by work center

bull Vehiclesequipment in process by work center

bull Vehiclesequipment deadlined for parts cannibalization is not a normal acceptable business practice replacement parts whether new rebuilt or refurbished or reconditioned will equal or exceed OEM standards

bull Vehiclesequipment awaiting outgoing inspection

bull Vehiclesequipment awaiting customer pickup

bull Work performed by outside contractor

133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures

Figure 1-1 illustrates recommended SRO flow procedures See NAVFAC P-300 Management of Civil Engineering Support Equipment for details on preparing SROs

NAVEDTRA 14264A 1-10

Customer brings vehicle

Customer completes hard card noting deficiencies

Will work exceed

3 hours

SRO prepared

Work performed

by in-house shop

SRO amp vehicle assigned to technician

Work accomplished

Work inspected

Other shop within

activity

CommercialContractor

OtherGovernment

Agency

Refer to P-300 4-195J

Refer to P-300 4-195H

Refer to P-300 4-195I

Is equipmentOwned byAnother Activity

Copies of SRO properly routed

Vehicle returned to customer

Refer to P-300

4-195G

Work assigned to technician

Work accomplished

Work inspected

SRO Process

Yes

No

No

No

No No No

Yes

Yes

YesYesYes

Figure 1-1 - Flow chart for Shop Repair Orders

134 Supply Support

For a maintenance organization to perform effectively it must receive responsive repair parts support This support requires a high degree of cooperation and communication between the management and staff of the shop and the shop store and between the Public Works Officer and the Supply Officer

The responsibilities involved must be understood and fulfilled Commander Naval Facilities Engineering Command (COMNAVFACENGCOM) and Commander Naval Supply Systems Command (COMNAVSUPSYSCOM) have recognized these understandings and promulgated them as policy outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment

1341 Public Works Responsibility to the Supply Department

bull Ensure that all initial support repair parts received in Public Works are turned over to the Supply Department for inventory control and accountability Initial support repair parts intended for activity stock should not be retained in the

NAVEDTRA 14264A 1-11

physical custody or records of the Supply Department once issued to the end user

bull Provide information regarding repair parts requirements needed to support vehiclesequipment on hand or for any new vehicleequipment received (Requirements would normally be generated from actual operational experience or through normal routine inspection of equipment)

bull Furnish advance information regarding repair parts requirements for scheduled overhauls (Requirements would be generated in the same manner outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment)

bull Provide technical assistance to the Transportation Shop store in identifying parts and insurance items and in determining parts interchangeability

bull Advise shop store of equipment scheduled for disposal or phase out and assist in identifying stocked items which should be eliminated from the shop store

bull In the absence of stock items provide end use Operation and Maintenance Navy (OampM N) funds to permit procurement and delivery of repair parts required for work in progress or for subsequent scheduled services and repair for which job orders have been issued

bull Conduct periodic follow-up of shop store parts orders (after required delivery date has passed) to ensure that appropriate action has been taken to reduce further delay

bull Encourage active coordinationcommunications between Public Works and Supply Department personnel

1342 Supply Department Responsibility to Public Works (Transportation)

bull Provide for the timeliest method of repair parts support through the use of available stock system stocks or purchase action using imprest fund or blanket purchase authority and indefinite delivery parts contracts (IDTC) when practical

bull Perform technical research for parts identification and to determine part numbers interchangeability and cross-referenced parts numbers

bull Collaborate with Public Works in establishing stock levels in support of current and projected vehicleequipment inventories

bull Record parts usage data for subsequent stock range and depth adjustments

bull Expedite local procurement action for immediate issue requirements when parts required are not readily available in the shop store or main supply department

bull Review outstanding requisitions regularly to ensure that status received indicates satisfactory supply action is in progress Follow up as necessary to obtain delivery status

bull Advise Public Works personnel promptly indicating delivery date(s) of requested repair parts

NAVEDTRA 14264A 1-12

bull Assume responsibility for staging of material by segregating material receipts applicable to specific repair jobs and advising the shop maintenance supervisor of material status

bull Encourage active coordinationcommunications between Supply Department and Public Works personnel

1343 Technical Parts Ordering Data

Surveys conducted by COMNAVFACENGCOM into the breakdown of repair parts support have revealed that much delay and downtime are caused by the mechanics failure to provide adequate technical data when requesting parts It should be standard practice in all maintenance shops to provide shop stores with the following information for all but common hardware and bulk material

bull Description of Major Unit Describe the vehicle or equipment unit for which the part is applicable such as Truck l2 ton 4 x 2 5000GVW

bull Manufacturer of Major Unit Give the make

bull Model of Major Unit Give manufacturers model designation

bull Year of Manufacture or Model Year Determine from nameplate

bull Vehicle Identification Number (VIN) Determine from nameplate

bull Description of Component Describe major component for which the part is required For example Engine V8 260 cubic inches Transmission Automatic 5 speed Allison Model AT-545 Component identification can be determined from manufacturers component line set lists provided with all new equipment (Manufacturers line set lists should be filed in the equipment history record jacket)

bull Manufacturer of Component Give make of major component when other than make of major unit

bull Serial Number of Component Give serial number from component nameplate where applicable

bull Description of Part Give full description of part using standard nomenclature with noun name first followed by descriptive modifiers such as sprocket camshaft kit carburetor Provide the part name when available however the correct part name is the responsibility of the parts person and should be verified Part numbers should be recorded on the SRO for future reference This practice saves research time for the parts person

135 Maintenance Forms

Proper use of appropriate forms is important to keep equipment maintained

1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)

The Operators Inspection Guide and Trouble Report is used by operators of motor vehicles to indicate the items they are required to inspect before and after operation It also serves as a means of transmitting information regarding deficiencies detected

NAVEDTRA 14264A 1-13

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

and prepares the NAVSUP Form 1250-2s to free floor mechanics to perform maintenance functions

115 Work Center Supervisor (3-M)

Work Center Supervisors are qualified and designated in writing They are responsible to the Division Officer via the Group Supervisor if applicable for the effective operation of the 3-M System within their respective Work Center Work Center Supervisor responsibilities are the following

bull Maintain a detailed working knowledge of all equipment deficiencies within the Work Center The Work Center Supervisor uses the Current Shiprsquos Maintenance Plan (CSMP) as a daily working document for the scheduling of any maintenance actions not included on the Preventive Maintenance Schedule (PMS) schedules

bull Schedule weekly Work Center maintenance and supervise its proper accomplishment

bull Ensure the status of Work Center planned maintenance is correctly reflected on the PMS schedules

bull Ensure the Division Officer or Group Supervisor if applicable is advised of all 3-M System activity within the Work Center

bull Maintain an adequate supply of 3-M System materials within the Work Center

bull Ensure prompt reporting of all material deficiencies and completed maintenance actions as required

bull Ensure all 3-M System documents submitted from the Work Center are correct legible and promptly prepared and submitted

bull Ensure maximum use of PMS as an aid for training personnel in maintenance procedures for equipment within the Work Center

bull Ensure 3-M System Work Center files publications MRC decks Tag Guide Lists (TGLs) and EGLs are complete and current

bull Review MRCs and promptly submit a PMS Feedback Report (FBR) whenever maintenance requirements are not fully understood errors are believed to exist maintenance requirements appear inadequate or excessive additional coverage is needed or performance of the maintenance requirement would cause a hazardous condition to exist

bull Ensure PMS covers all equipment in the Work Center Maintain an accurate and current List of Effective Pages (LOEP) by comparing the documentation with the actual equipment configuration Submit PMS FBR when changes to the LOEP are required Submit configuration change requests when appropriate

bull Ensure programmed Periodic Maintenance Requirements (PMRs) scheduled for ships force accomplishment are completed and reported in strict accordance with the PMR if applicable

bull Ensure proper testing and inspection of work done by outside activities prior to job acceptance

NAVEDTRA 14264A 1-7

bull Ensure delivery of test and measurement equipment and other portable support equipment to testing and calibration Work Centers as indicated on scheduling reports

120 Maintenance Categories The goal of maintenance is to keep equipment in a safe and serviceable condition at all times at reasonable costs and to detect minor deficiencies before they develop into costly repairs The Maintenance System of the Naval Construction Force (NCF) is predicated on three categories or levels of maintenance and 3-M Organizational Intermediate and Depot The category of repairs performed is determined by the following

bull Nature of the repair

bull Level of repair parts support tools equipment and time available

bull Personnel capabilities

bull Tactical situation

An activitys range of repair parts support is keyed to the authorized level of maintenance

121 Organizational Maintenance

Organizational maintenance is that maintenance which is the responsibility of and performed by the operator and scheduled preventive maintenance services performed by trained personnel Organizational maintenance consists of proper equipment operation safety and serviceability inspections lubrication minor adjustments and services in accordance with the MRC Organizational maintenance is divided into operator and preventive maintenance as specified below

1211 Operator Maintenance

Each operator is required to perform work needed to maintain his or her vehicle in a clean safe and serviceable condition Operator maintenance includes the daily inspections before during and after operation It also includes periodic lubrication and adjustments These requirements are completed utilizing the pertinent MRC Operator maintenance is performed to ensure early detection of deficiencies

1212 Preventive Maintenance

Preventive maintenance is that maintenance which is scheduled for the purpose of maximizing equipment availability and minimizing repair costs Preventive maintenance consists of safety and mechanical inspections lubrication and services and adjustments beyond an operators responsibility Operators should assist with this work unless directed otherwise Maintenance support requiring more extensive services is categorized as Corrective level maintenance

122 Corrective Maintenance

Corrective maintenance is that maintenance which is the responsibility of and performed in any designated maintenance shop The extent of corrective maintenance

NAVEDTRA 14264A 1-8

encompasses the removal replacement repair alteration calibration modification and the rebuild and overhaul of individual assemblies subassemblies and components Although the rebuild and overhaul of major assemblies are included only essential repairs should be accomplished to ensure safe and serviceable equipment Equipment that requires extensive repairs or numerous assembly rebuilds will not be repaired without prior approval by higher authority Corrective maintenance requires a higher degree of skill than organizational maintenance and a larger assortment of repair parts and more precision tools and test equipment

To preclude the possibility of the installation of expensive components on equipment which may be scheduled for excess survey or overhaul field units must request authority from the respective Regimental (R43) Equipment Office representative prior to the purchase of component parts costing in excess of $1000 or a total repair cost in excess of $2500

123 Depot Maintenance

Depot maintenance is that maintenance performed on equipment that requires major overhaul or comprehensive restoration to a degree necessary to restore the entire unit to a like-new condition

130 Maintenance Scheduling

131 Scheduling and Shop Control

An effective and efficient maintenance program requires the establishment and upkeep of a preventive maintenance scheduling system and a sound shop control procedure Vehicles and equipment should be scheduled for inspection and servicing in accordance with the time mileage and operating hours prescribed in NAVFAC P-300 Management of Civil Engineering Support Equipment and the Material Maintenance Management Program (3M) As a minimum the schedule should ensure that each vehicle is inspected for safety at least every 12 months or 12000 miles whichever occurs first The schedule can be formulated as follows

1 Determine the number of service intervals per year per vehicle by determining each vehiclersquos estimated annual miles and then dividing by the manufacturerrsquos recommended service interval

2 Develop the number of working days between each inspection (designated inspection group) for each vehicle by dividing the number of working days per year (250) by the number of service intervals per year

3 Establish a schedule from this determination that provides a quota of vehicles for inspection daily and a balanced shop workload

Use an electronic record to track service intervals and service performed The record should include the following

bull USN

bull EC

bull Make

bull Model NAVEDTRA 14264A 1-9

bull Year

bull Estimated annual mileshours

bull Type of service

bull Date

bull Cumulative mileage or hours

bull Miles or hours of operation

bull Miles or hours operated or a specified interval

132 Shop Workload

The best method for accomplishing positive direction of shop workload is to identify and keep the following information current

bull Available work force by work center

bull Vehiclesequipment awaiting input by work center

bull Vehiclesequipment in process by work center

bull Vehiclesequipment deadlined for parts cannibalization is not a normal acceptable business practice replacement parts whether new rebuilt or refurbished or reconditioned will equal or exceed OEM standards

bull Vehiclesequipment awaiting outgoing inspection

bull Vehiclesequipment awaiting customer pickup

bull Work performed by outside contractor

133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures

Figure 1-1 illustrates recommended SRO flow procedures See NAVFAC P-300 Management of Civil Engineering Support Equipment for details on preparing SROs

NAVEDTRA 14264A 1-10

Customer brings vehicle

Customer completes hard card noting deficiencies

Will work exceed

3 hours

SRO prepared

Work performed

by in-house shop

SRO amp vehicle assigned to technician

Work accomplished

Work inspected

Other shop within

activity

CommercialContractor

OtherGovernment

Agency

Refer to P-300 4-195J

Refer to P-300 4-195H

Refer to P-300 4-195I

Is equipmentOwned byAnother Activity

Copies of SRO properly routed

Vehicle returned to customer

Refer to P-300

4-195G

Work assigned to technician

Work accomplished

Work inspected

SRO Process

Yes

No

No

No

No No No

Yes

Yes

YesYesYes

Figure 1-1 - Flow chart for Shop Repair Orders

134 Supply Support

For a maintenance organization to perform effectively it must receive responsive repair parts support This support requires a high degree of cooperation and communication between the management and staff of the shop and the shop store and between the Public Works Officer and the Supply Officer

The responsibilities involved must be understood and fulfilled Commander Naval Facilities Engineering Command (COMNAVFACENGCOM) and Commander Naval Supply Systems Command (COMNAVSUPSYSCOM) have recognized these understandings and promulgated them as policy outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment

1341 Public Works Responsibility to the Supply Department

bull Ensure that all initial support repair parts received in Public Works are turned over to the Supply Department for inventory control and accountability Initial support repair parts intended for activity stock should not be retained in the

NAVEDTRA 14264A 1-11

physical custody or records of the Supply Department once issued to the end user

bull Provide information regarding repair parts requirements needed to support vehiclesequipment on hand or for any new vehicleequipment received (Requirements would normally be generated from actual operational experience or through normal routine inspection of equipment)

bull Furnish advance information regarding repair parts requirements for scheduled overhauls (Requirements would be generated in the same manner outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment)

bull Provide technical assistance to the Transportation Shop store in identifying parts and insurance items and in determining parts interchangeability

bull Advise shop store of equipment scheduled for disposal or phase out and assist in identifying stocked items which should be eliminated from the shop store

bull In the absence of stock items provide end use Operation and Maintenance Navy (OampM N) funds to permit procurement and delivery of repair parts required for work in progress or for subsequent scheduled services and repair for which job orders have been issued

bull Conduct periodic follow-up of shop store parts orders (after required delivery date has passed) to ensure that appropriate action has been taken to reduce further delay

bull Encourage active coordinationcommunications between Public Works and Supply Department personnel

1342 Supply Department Responsibility to Public Works (Transportation)

bull Provide for the timeliest method of repair parts support through the use of available stock system stocks or purchase action using imprest fund or blanket purchase authority and indefinite delivery parts contracts (IDTC) when practical

bull Perform technical research for parts identification and to determine part numbers interchangeability and cross-referenced parts numbers

bull Collaborate with Public Works in establishing stock levels in support of current and projected vehicleequipment inventories

bull Record parts usage data for subsequent stock range and depth adjustments

bull Expedite local procurement action for immediate issue requirements when parts required are not readily available in the shop store or main supply department

bull Review outstanding requisitions regularly to ensure that status received indicates satisfactory supply action is in progress Follow up as necessary to obtain delivery status

bull Advise Public Works personnel promptly indicating delivery date(s) of requested repair parts

NAVEDTRA 14264A 1-12

bull Assume responsibility for staging of material by segregating material receipts applicable to specific repair jobs and advising the shop maintenance supervisor of material status

bull Encourage active coordinationcommunications between Supply Department and Public Works personnel

1343 Technical Parts Ordering Data

Surveys conducted by COMNAVFACENGCOM into the breakdown of repair parts support have revealed that much delay and downtime are caused by the mechanics failure to provide adequate technical data when requesting parts It should be standard practice in all maintenance shops to provide shop stores with the following information for all but common hardware and bulk material

bull Description of Major Unit Describe the vehicle or equipment unit for which the part is applicable such as Truck l2 ton 4 x 2 5000GVW

bull Manufacturer of Major Unit Give the make

bull Model of Major Unit Give manufacturers model designation

bull Year of Manufacture or Model Year Determine from nameplate

bull Vehicle Identification Number (VIN) Determine from nameplate

bull Description of Component Describe major component for which the part is required For example Engine V8 260 cubic inches Transmission Automatic 5 speed Allison Model AT-545 Component identification can be determined from manufacturers component line set lists provided with all new equipment (Manufacturers line set lists should be filed in the equipment history record jacket)

bull Manufacturer of Component Give make of major component when other than make of major unit

bull Serial Number of Component Give serial number from component nameplate where applicable

bull Description of Part Give full description of part using standard nomenclature with noun name first followed by descriptive modifiers such as sprocket camshaft kit carburetor Provide the part name when available however the correct part name is the responsibility of the parts person and should be verified Part numbers should be recorded on the SRO for future reference This practice saves research time for the parts person

135 Maintenance Forms

Proper use of appropriate forms is important to keep equipment maintained

1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)

The Operators Inspection Guide and Trouble Report is used by operators of motor vehicles to indicate the items they are required to inspect before and after operation It also serves as a means of transmitting information regarding deficiencies detected

NAVEDTRA 14264A 1-13

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  143. txtCourse
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  145. txtChapter
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  147. txtDescription
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  148. txtCorrection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

bull Ensure delivery of test and measurement equipment and other portable support equipment to testing and calibration Work Centers as indicated on scheduling reports

120 Maintenance Categories The goal of maintenance is to keep equipment in a safe and serviceable condition at all times at reasonable costs and to detect minor deficiencies before they develop into costly repairs The Maintenance System of the Naval Construction Force (NCF) is predicated on three categories or levels of maintenance and 3-M Organizational Intermediate and Depot The category of repairs performed is determined by the following

bull Nature of the repair

bull Level of repair parts support tools equipment and time available

bull Personnel capabilities

bull Tactical situation

An activitys range of repair parts support is keyed to the authorized level of maintenance

121 Organizational Maintenance

Organizational maintenance is that maintenance which is the responsibility of and performed by the operator and scheduled preventive maintenance services performed by trained personnel Organizational maintenance consists of proper equipment operation safety and serviceability inspections lubrication minor adjustments and services in accordance with the MRC Organizational maintenance is divided into operator and preventive maintenance as specified below

1211 Operator Maintenance

Each operator is required to perform work needed to maintain his or her vehicle in a clean safe and serviceable condition Operator maintenance includes the daily inspections before during and after operation It also includes periodic lubrication and adjustments These requirements are completed utilizing the pertinent MRC Operator maintenance is performed to ensure early detection of deficiencies

1212 Preventive Maintenance

Preventive maintenance is that maintenance which is scheduled for the purpose of maximizing equipment availability and minimizing repair costs Preventive maintenance consists of safety and mechanical inspections lubrication and services and adjustments beyond an operators responsibility Operators should assist with this work unless directed otherwise Maintenance support requiring more extensive services is categorized as Corrective level maintenance

122 Corrective Maintenance

Corrective maintenance is that maintenance which is the responsibility of and performed in any designated maintenance shop The extent of corrective maintenance

NAVEDTRA 14264A 1-8

encompasses the removal replacement repair alteration calibration modification and the rebuild and overhaul of individual assemblies subassemblies and components Although the rebuild and overhaul of major assemblies are included only essential repairs should be accomplished to ensure safe and serviceable equipment Equipment that requires extensive repairs or numerous assembly rebuilds will not be repaired without prior approval by higher authority Corrective maintenance requires a higher degree of skill than organizational maintenance and a larger assortment of repair parts and more precision tools and test equipment

To preclude the possibility of the installation of expensive components on equipment which may be scheduled for excess survey or overhaul field units must request authority from the respective Regimental (R43) Equipment Office representative prior to the purchase of component parts costing in excess of $1000 or a total repair cost in excess of $2500

123 Depot Maintenance

Depot maintenance is that maintenance performed on equipment that requires major overhaul or comprehensive restoration to a degree necessary to restore the entire unit to a like-new condition

130 Maintenance Scheduling

131 Scheduling and Shop Control

An effective and efficient maintenance program requires the establishment and upkeep of a preventive maintenance scheduling system and a sound shop control procedure Vehicles and equipment should be scheduled for inspection and servicing in accordance with the time mileage and operating hours prescribed in NAVFAC P-300 Management of Civil Engineering Support Equipment and the Material Maintenance Management Program (3M) As a minimum the schedule should ensure that each vehicle is inspected for safety at least every 12 months or 12000 miles whichever occurs first The schedule can be formulated as follows

1 Determine the number of service intervals per year per vehicle by determining each vehiclersquos estimated annual miles and then dividing by the manufacturerrsquos recommended service interval

2 Develop the number of working days between each inspection (designated inspection group) for each vehicle by dividing the number of working days per year (250) by the number of service intervals per year

3 Establish a schedule from this determination that provides a quota of vehicles for inspection daily and a balanced shop workload

Use an electronic record to track service intervals and service performed The record should include the following

bull USN

bull EC

bull Make

bull Model NAVEDTRA 14264A 1-9

bull Year

bull Estimated annual mileshours

bull Type of service

bull Date

bull Cumulative mileage or hours

bull Miles or hours of operation

bull Miles or hours operated or a specified interval

132 Shop Workload

The best method for accomplishing positive direction of shop workload is to identify and keep the following information current

bull Available work force by work center

bull Vehiclesequipment awaiting input by work center

bull Vehiclesequipment in process by work center

bull Vehiclesequipment deadlined for parts cannibalization is not a normal acceptable business practice replacement parts whether new rebuilt or refurbished or reconditioned will equal or exceed OEM standards

bull Vehiclesequipment awaiting outgoing inspection

bull Vehiclesequipment awaiting customer pickup

bull Work performed by outside contractor

133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures

Figure 1-1 illustrates recommended SRO flow procedures See NAVFAC P-300 Management of Civil Engineering Support Equipment for details on preparing SROs

NAVEDTRA 14264A 1-10

Customer brings vehicle

Customer completes hard card noting deficiencies

Will work exceed

3 hours

SRO prepared

Work performed

by in-house shop

SRO amp vehicle assigned to technician

Work accomplished

Work inspected

Other shop within

activity

CommercialContractor

OtherGovernment

Agency

Refer to P-300 4-195J

Refer to P-300 4-195H

Refer to P-300 4-195I

Is equipmentOwned byAnother Activity

Copies of SRO properly routed

Vehicle returned to customer

Refer to P-300

4-195G

Work assigned to technician

Work accomplished

Work inspected

SRO Process

Yes

No

No

No

No No No

Yes

Yes

YesYesYes

Figure 1-1 - Flow chart for Shop Repair Orders

134 Supply Support

For a maintenance organization to perform effectively it must receive responsive repair parts support This support requires a high degree of cooperation and communication between the management and staff of the shop and the shop store and between the Public Works Officer and the Supply Officer

The responsibilities involved must be understood and fulfilled Commander Naval Facilities Engineering Command (COMNAVFACENGCOM) and Commander Naval Supply Systems Command (COMNAVSUPSYSCOM) have recognized these understandings and promulgated them as policy outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment

1341 Public Works Responsibility to the Supply Department

bull Ensure that all initial support repair parts received in Public Works are turned over to the Supply Department for inventory control and accountability Initial support repair parts intended for activity stock should not be retained in the

NAVEDTRA 14264A 1-11

physical custody or records of the Supply Department once issued to the end user

bull Provide information regarding repair parts requirements needed to support vehiclesequipment on hand or for any new vehicleequipment received (Requirements would normally be generated from actual operational experience or through normal routine inspection of equipment)

bull Furnish advance information regarding repair parts requirements for scheduled overhauls (Requirements would be generated in the same manner outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment)

bull Provide technical assistance to the Transportation Shop store in identifying parts and insurance items and in determining parts interchangeability

bull Advise shop store of equipment scheduled for disposal or phase out and assist in identifying stocked items which should be eliminated from the shop store

bull In the absence of stock items provide end use Operation and Maintenance Navy (OampM N) funds to permit procurement and delivery of repair parts required for work in progress or for subsequent scheduled services and repair for which job orders have been issued

bull Conduct periodic follow-up of shop store parts orders (after required delivery date has passed) to ensure that appropriate action has been taken to reduce further delay

bull Encourage active coordinationcommunications between Public Works and Supply Department personnel

1342 Supply Department Responsibility to Public Works (Transportation)

bull Provide for the timeliest method of repair parts support through the use of available stock system stocks or purchase action using imprest fund or blanket purchase authority and indefinite delivery parts contracts (IDTC) when practical

bull Perform technical research for parts identification and to determine part numbers interchangeability and cross-referenced parts numbers

bull Collaborate with Public Works in establishing stock levels in support of current and projected vehicleequipment inventories

bull Record parts usage data for subsequent stock range and depth adjustments

bull Expedite local procurement action for immediate issue requirements when parts required are not readily available in the shop store or main supply department

bull Review outstanding requisitions regularly to ensure that status received indicates satisfactory supply action is in progress Follow up as necessary to obtain delivery status

bull Advise Public Works personnel promptly indicating delivery date(s) of requested repair parts

NAVEDTRA 14264A 1-12

bull Assume responsibility for staging of material by segregating material receipts applicable to specific repair jobs and advising the shop maintenance supervisor of material status

bull Encourage active coordinationcommunications between Supply Department and Public Works personnel

1343 Technical Parts Ordering Data

Surveys conducted by COMNAVFACENGCOM into the breakdown of repair parts support have revealed that much delay and downtime are caused by the mechanics failure to provide adequate technical data when requesting parts It should be standard practice in all maintenance shops to provide shop stores with the following information for all but common hardware and bulk material

bull Description of Major Unit Describe the vehicle or equipment unit for which the part is applicable such as Truck l2 ton 4 x 2 5000GVW

bull Manufacturer of Major Unit Give the make

bull Model of Major Unit Give manufacturers model designation

bull Year of Manufacture or Model Year Determine from nameplate

bull Vehicle Identification Number (VIN) Determine from nameplate

bull Description of Component Describe major component for which the part is required For example Engine V8 260 cubic inches Transmission Automatic 5 speed Allison Model AT-545 Component identification can be determined from manufacturers component line set lists provided with all new equipment (Manufacturers line set lists should be filed in the equipment history record jacket)

bull Manufacturer of Component Give make of major component when other than make of major unit

bull Serial Number of Component Give serial number from component nameplate where applicable

bull Description of Part Give full description of part using standard nomenclature with noun name first followed by descriptive modifiers such as sprocket camshaft kit carburetor Provide the part name when available however the correct part name is the responsibility of the parts person and should be verified Part numbers should be recorded on the SRO for future reference This practice saves research time for the parts person

135 Maintenance Forms

Proper use of appropriate forms is important to keep equipment maintained

1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)

The Operators Inspection Guide and Trouble Report is used by operators of motor vehicles to indicate the items they are required to inspect before and after operation It also serves as a means of transmitting information regarding deficiencies detected

NAVEDTRA 14264A 1-13

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  145. txtChapter
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  147. txtDescription
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  148. txtCorrection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

encompasses the removal replacement repair alteration calibration modification and the rebuild and overhaul of individual assemblies subassemblies and components Although the rebuild and overhaul of major assemblies are included only essential repairs should be accomplished to ensure safe and serviceable equipment Equipment that requires extensive repairs or numerous assembly rebuilds will not be repaired without prior approval by higher authority Corrective maintenance requires a higher degree of skill than organizational maintenance and a larger assortment of repair parts and more precision tools and test equipment

To preclude the possibility of the installation of expensive components on equipment which may be scheduled for excess survey or overhaul field units must request authority from the respective Regimental (R43) Equipment Office representative prior to the purchase of component parts costing in excess of $1000 or a total repair cost in excess of $2500

123 Depot Maintenance

Depot maintenance is that maintenance performed on equipment that requires major overhaul or comprehensive restoration to a degree necessary to restore the entire unit to a like-new condition

130 Maintenance Scheduling

131 Scheduling and Shop Control

An effective and efficient maintenance program requires the establishment and upkeep of a preventive maintenance scheduling system and a sound shop control procedure Vehicles and equipment should be scheduled for inspection and servicing in accordance with the time mileage and operating hours prescribed in NAVFAC P-300 Management of Civil Engineering Support Equipment and the Material Maintenance Management Program (3M) As a minimum the schedule should ensure that each vehicle is inspected for safety at least every 12 months or 12000 miles whichever occurs first The schedule can be formulated as follows

1 Determine the number of service intervals per year per vehicle by determining each vehiclersquos estimated annual miles and then dividing by the manufacturerrsquos recommended service interval

2 Develop the number of working days between each inspection (designated inspection group) for each vehicle by dividing the number of working days per year (250) by the number of service intervals per year

3 Establish a schedule from this determination that provides a quota of vehicles for inspection daily and a balanced shop workload

Use an electronic record to track service intervals and service performed The record should include the following

bull USN

bull EC

bull Make

bull Model NAVEDTRA 14264A 1-9

bull Year

bull Estimated annual mileshours

bull Type of service

bull Date

bull Cumulative mileage or hours

bull Miles or hours of operation

bull Miles or hours operated or a specified interval

132 Shop Workload

The best method for accomplishing positive direction of shop workload is to identify and keep the following information current

bull Available work force by work center

bull Vehiclesequipment awaiting input by work center

bull Vehiclesequipment in process by work center

bull Vehiclesequipment deadlined for parts cannibalization is not a normal acceptable business practice replacement parts whether new rebuilt or refurbished or reconditioned will equal or exceed OEM standards

bull Vehiclesequipment awaiting outgoing inspection

bull Vehiclesequipment awaiting customer pickup

bull Work performed by outside contractor

133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures

Figure 1-1 illustrates recommended SRO flow procedures See NAVFAC P-300 Management of Civil Engineering Support Equipment for details on preparing SROs

NAVEDTRA 14264A 1-10

Customer brings vehicle

Customer completes hard card noting deficiencies

Will work exceed

3 hours

SRO prepared

Work performed

by in-house shop

SRO amp vehicle assigned to technician

Work accomplished

Work inspected

Other shop within

activity

CommercialContractor

OtherGovernment

Agency

Refer to P-300 4-195J

Refer to P-300 4-195H

Refer to P-300 4-195I

Is equipmentOwned byAnother Activity

Copies of SRO properly routed

Vehicle returned to customer

Refer to P-300

4-195G

Work assigned to technician

Work accomplished

Work inspected

SRO Process

Yes

No

No

No

No No No

Yes

Yes

YesYesYes

Figure 1-1 - Flow chart for Shop Repair Orders

134 Supply Support

For a maintenance organization to perform effectively it must receive responsive repair parts support This support requires a high degree of cooperation and communication between the management and staff of the shop and the shop store and between the Public Works Officer and the Supply Officer

The responsibilities involved must be understood and fulfilled Commander Naval Facilities Engineering Command (COMNAVFACENGCOM) and Commander Naval Supply Systems Command (COMNAVSUPSYSCOM) have recognized these understandings and promulgated them as policy outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment

1341 Public Works Responsibility to the Supply Department

bull Ensure that all initial support repair parts received in Public Works are turned over to the Supply Department for inventory control and accountability Initial support repair parts intended for activity stock should not be retained in the

NAVEDTRA 14264A 1-11

physical custody or records of the Supply Department once issued to the end user

bull Provide information regarding repair parts requirements needed to support vehiclesequipment on hand or for any new vehicleequipment received (Requirements would normally be generated from actual operational experience or through normal routine inspection of equipment)

bull Furnish advance information regarding repair parts requirements for scheduled overhauls (Requirements would be generated in the same manner outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment)

bull Provide technical assistance to the Transportation Shop store in identifying parts and insurance items and in determining parts interchangeability

bull Advise shop store of equipment scheduled for disposal or phase out and assist in identifying stocked items which should be eliminated from the shop store

bull In the absence of stock items provide end use Operation and Maintenance Navy (OampM N) funds to permit procurement and delivery of repair parts required for work in progress or for subsequent scheduled services and repair for which job orders have been issued

bull Conduct periodic follow-up of shop store parts orders (after required delivery date has passed) to ensure that appropriate action has been taken to reduce further delay

bull Encourage active coordinationcommunications between Public Works and Supply Department personnel

1342 Supply Department Responsibility to Public Works (Transportation)

bull Provide for the timeliest method of repair parts support through the use of available stock system stocks or purchase action using imprest fund or blanket purchase authority and indefinite delivery parts contracts (IDTC) when practical

bull Perform technical research for parts identification and to determine part numbers interchangeability and cross-referenced parts numbers

bull Collaborate with Public Works in establishing stock levels in support of current and projected vehicleequipment inventories

bull Record parts usage data for subsequent stock range and depth adjustments

bull Expedite local procurement action for immediate issue requirements when parts required are not readily available in the shop store or main supply department

bull Review outstanding requisitions regularly to ensure that status received indicates satisfactory supply action is in progress Follow up as necessary to obtain delivery status

bull Advise Public Works personnel promptly indicating delivery date(s) of requested repair parts

NAVEDTRA 14264A 1-12

bull Assume responsibility for staging of material by segregating material receipts applicable to specific repair jobs and advising the shop maintenance supervisor of material status

bull Encourage active coordinationcommunications between Supply Department and Public Works personnel

1343 Technical Parts Ordering Data

Surveys conducted by COMNAVFACENGCOM into the breakdown of repair parts support have revealed that much delay and downtime are caused by the mechanics failure to provide adequate technical data when requesting parts It should be standard practice in all maintenance shops to provide shop stores with the following information for all but common hardware and bulk material

bull Description of Major Unit Describe the vehicle or equipment unit for which the part is applicable such as Truck l2 ton 4 x 2 5000GVW

bull Manufacturer of Major Unit Give the make

bull Model of Major Unit Give manufacturers model designation

bull Year of Manufacture or Model Year Determine from nameplate

bull Vehicle Identification Number (VIN) Determine from nameplate

bull Description of Component Describe major component for which the part is required For example Engine V8 260 cubic inches Transmission Automatic 5 speed Allison Model AT-545 Component identification can be determined from manufacturers component line set lists provided with all new equipment (Manufacturers line set lists should be filed in the equipment history record jacket)

bull Manufacturer of Component Give make of major component when other than make of major unit

bull Serial Number of Component Give serial number from component nameplate where applicable

bull Description of Part Give full description of part using standard nomenclature with noun name first followed by descriptive modifiers such as sprocket camshaft kit carburetor Provide the part name when available however the correct part name is the responsibility of the parts person and should be verified Part numbers should be recorded on the SRO for future reference This practice saves research time for the parts person

135 Maintenance Forms

Proper use of appropriate forms is important to keep equipment maintained

1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)

The Operators Inspection Guide and Trouble Report is used by operators of motor vehicles to indicate the items they are required to inspect before and after operation It also serves as a means of transmitting information regarding deficiencies detected

NAVEDTRA 14264A 1-13

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  142. txtRate
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

bull Year

bull Estimated annual mileshours

bull Type of service

bull Date

bull Cumulative mileage or hours

bull Miles or hours of operation

bull Miles or hours operated or a specified interval

132 Shop Workload

The best method for accomplishing positive direction of shop workload is to identify and keep the following information current

bull Available work force by work center

bull Vehiclesequipment awaiting input by work center

bull Vehiclesequipment in process by work center

bull Vehiclesequipment deadlined for parts cannibalization is not a normal acceptable business practice replacement parts whether new rebuilt or refurbished or reconditioned will equal or exceed OEM standards

bull Vehiclesequipment awaiting outgoing inspection

bull Vehiclesequipment awaiting customer pickup

bull Work performed by outside contractor

133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures

Figure 1-1 illustrates recommended SRO flow procedures See NAVFAC P-300 Management of Civil Engineering Support Equipment for details on preparing SROs

NAVEDTRA 14264A 1-10

Customer brings vehicle

Customer completes hard card noting deficiencies

Will work exceed

3 hours

SRO prepared

Work performed

by in-house shop

SRO amp vehicle assigned to technician

Work accomplished

Work inspected

Other shop within

activity

CommercialContractor

OtherGovernment

Agency

Refer to P-300 4-195J

Refer to P-300 4-195H

Refer to P-300 4-195I

Is equipmentOwned byAnother Activity

Copies of SRO properly routed

Vehicle returned to customer

Refer to P-300

4-195G

Work assigned to technician

Work accomplished

Work inspected

SRO Process

Yes

No

No

No

No No No

Yes

Yes

YesYesYes

Figure 1-1 - Flow chart for Shop Repair Orders

134 Supply Support

For a maintenance organization to perform effectively it must receive responsive repair parts support This support requires a high degree of cooperation and communication between the management and staff of the shop and the shop store and between the Public Works Officer and the Supply Officer

The responsibilities involved must be understood and fulfilled Commander Naval Facilities Engineering Command (COMNAVFACENGCOM) and Commander Naval Supply Systems Command (COMNAVSUPSYSCOM) have recognized these understandings and promulgated them as policy outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment

1341 Public Works Responsibility to the Supply Department

bull Ensure that all initial support repair parts received in Public Works are turned over to the Supply Department for inventory control and accountability Initial support repair parts intended for activity stock should not be retained in the

NAVEDTRA 14264A 1-11

physical custody or records of the Supply Department once issued to the end user

bull Provide information regarding repair parts requirements needed to support vehiclesequipment on hand or for any new vehicleequipment received (Requirements would normally be generated from actual operational experience or through normal routine inspection of equipment)

bull Furnish advance information regarding repair parts requirements for scheduled overhauls (Requirements would be generated in the same manner outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment)

bull Provide technical assistance to the Transportation Shop store in identifying parts and insurance items and in determining parts interchangeability

bull Advise shop store of equipment scheduled for disposal or phase out and assist in identifying stocked items which should be eliminated from the shop store

bull In the absence of stock items provide end use Operation and Maintenance Navy (OampM N) funds to permit procurement and delivery of repair parts required for work in progress or for subsequent scheduled services and repair for which job orders have been issued

bull Conduct periodic follow-up of shop store parts orders (after required delivery date has passed) to ensure that appropriate action has been taken to reduce further delay

bull Encourage active coordinationcommunications between Public Works and Supply Department personnel

1342 Supply Department Responsibility to Public Works (Transportation)

bull Provide for the timeliest method of repair parts support through the use of available stock system stocks or purchase action using imprest fund or blanket purchase authority and indefinite delivery parts contracts (IDTC) when practical

bull Perform technical research for parts identification and to determine part numbers interchangeability and cross-referenced parts numbers

bull Collaborate with Public Works in establishing stock levels in support of current and projected vehicleequipment inventories

bull Record parts usage data for subsequent stock range and depth adjustments

bull Expedite local procurement action for immediate issue requirements when parts required are not readily available in the shop store or main supply department

bull Review outstanding requisitions regularly to ensure that status received indicates satisfactory supply action is in progress Follow up as necessary to obtain delivery status

bull Advise Public Works personnel promptly indicating delivery date(s) of requested repair parts

NAVEDTRA 14264A 1-12

bull Assume responsibility for staging of material by segregating material receipts applicable to specific repair jobs and advising the shop maintenance supervisor of material status

bull Encourage active coordinationcommunications between Supply Department and Public Works personnel

1343 Technical Parts Ordering Data

Surveys conducted by COMNAVFACENGCOM into the breakdown of repair parts support have revealed that much delay and downtime are caused by the mechanics failure to provide adequate technical data when requesting parts It should be standard practice in all maintenance shops to provide shop stores with the following information for all but common hardware and bulk material

bull Description of Major Unit Describe the vehicle or equipment unit for which the part is applicable such as Truck l2 ton 4 x 2 5000GVW

bull Manufacturer of Major Unit Give the make

bull Model of Major Unit Give manufacturers model designation

bull Year of Manufacture or Model Year Determine from nameplate

bull Vehicle Identification Number (VIN) Determine from nameplate

bull Description of Component Describe major component for which the part is required For example Engine V8 260 cubic inches Transmission Automatic 5 speed Allison Model AT-545 Component identification can be determined from manufacturers component line set lists provided with all new equipment (Manufacturers line set lists should be filed in the equipment history record jacket)

bull Manufacturer of Component Give make of major component when other than make of major unit

bull Serial Number of Component Give serial number from component nameplate where applicable

bull Description of Part Give full description of part using standard nomenclature with noun name first followed by descriptive modifiers such as sprocket camshaft kit carburetor Provide the part name when available however the correct part name is the responsibility of the parts person and should be verified Part numbers should be recorded on the SRO for future reference This practice saves research time for the parts person

135 Maintenance Forms

Proper use of appropriate forms is important to keep equipment maintained

1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)

The Operators Inspection Guide and Trouble Report is used by operators of motor vehicles to indicate the items they are required to inspect before and after operation It also serves as a means of transmitting information regarding deficiencies detected

NAVEDTRA 14264A 1-13

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

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NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  1. returnTxt1CMB01PG3 Remediation Page Click anywhere on this page to return
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  142. txtRate
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  144. txtDate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  145. txtChapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  146. txtPage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  147. txtDescription
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  148. txtCorrection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

Customer brings vehicle

Customer completes hard card noting deficiencies

Will work exceed

3 hours

SRO prepared

Work performed

by in-house shop

SRO amp vehicle assigned to technician

Work accomplished

Work inspected

Other shop within

activity

CommercialContractor

OtherGovernment

Agency

Refer to P-300 4-195J

Refer to P-300 4-195H

Refer to P-300 4-195I

Is equipmentOwned byAnother Activity

Copies of SRO properly routed

Vehicle returned to customer

Refer to P-300

4-195G

Work assigned to technician

Work accomplished

Work inspected

SRO Process

Yes

No

No

No

No No No

Yes

Yes

YesYesYes

Figure 1-1 - Flow chart for Shop Repair Orders

134 Supply Support

For a maintenance organization to perform effectively it must receive responsive repair parts support This support requires a high degree of cooperation and communication between the management and staff of the shop and the shop store and between the Public Works Officer and the Supply Officer

The responsibilities involved must be understood and fulfilled Commander Naval Facilities Engineering Command (COMNAVFACENGCOM) and Commander Naval Supply Systems Command (COMNAVSUPSYSCOM) have recognized these understandings and promulgated them as policy outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment

1341 Public Works Responsibility to the Supply Department

bull Ensure that all initial support repair parts received in Public Works are turned over to the Supply Department for inventory control and accountability Initial support repair parts intended for activity stock should not be retained in the

NAVEDTRA 14264A 1-11

physical custody or records of the Supply Department once issued to the end user

bull Provide information regarding repair parts requirements needed to support vehiclesequipment on hand or for any new vehicleequipment received (Requirements would normally be generated from actual operational experience or through normal routine inspection of equipment)

bull Furnish advance information regarding repair parts requirements for scheduled overhauls (Requirements would be generated in the same manner outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment)

bull Provide technical assistance to the Transportation Shop store in identifying parts and insurance items and in determining parts interchangeability

bull Advise shop store of equipment scheduled for disposal or phase out and assist in identifying stocked items which should be eliminated from the shop store

bull In the absence of stock items provide end use Operation and Maintenance Navy (OampM N) funds to permit procurement and delivery of repair parts required for work in progress or for subsequent scheduled services and repair for which job orders have been issued

bull Conduct periodic follow-up of shop store parts orders (after required delivery date has passed) to ensure that appropriate action has been taken to reduce further delay

bull Encourage active coordinationcommunications between Public Works and Supply Department personnel

1342 Supply Department Responsibility to Public Works (Transportation)

bull Provide for the timeliest method of repair parts support through the use of available stock system stocks or purchase action using imprest fund or blanket purchase authority and indefinite delivery parts contracts (IDTC) when practical

bull Perform technical research for parts identification and to determine part numbers interchangeability and cross-referenced parts numbers

bull Collaborate with Public Works in establishing stock levels in support of current and projected vehicleequipment inventories

bull Record parts usage data for subsequent stock range and depth adjustments

bull Expedite local procurement action for immediate issue requirements when parts required are not readily available in the shop store or main supply department

bull Review outstanding requisitions regularly to ensure that status received indicates satisfactory supply action is in progress Follow up as necessary to obtain delivery status

bull Advise Public Works personnel promptly indicating delivery date(s) of requested repair parts

NAVEDTRA 14264A 1-12

bull Assume responsibility for staging of material by segregating material receipts applicable to specific repair jobs and advising the shop maintenance supervisor of material status

bull Encourage active coordinationcommunications between Supply Department and Public Works personnel

1343 Technical Parts Ordering Data

Surveys conducted by COMNAVFACENGCOM into the breakdown of repair parts support have revealed that much delay and downtime are caused by the mechanics failure to provide adequate technical data when requesting parts It should be standard practice in all maintenance shops to provide shop stores with the following information for all but common hardware and bulk material

bull Description of Major Unit Describe the vehicle or equipment unit for which the part is applicable such as Truck l2 ton 4 x 2 5000GVW

bull Manufacturer of Major Unit Give the make

bull Model of Major Unit Give manufacturers model designation

bull Year of Manufacture or Model Year Determine from nameplate

bull Vehicle Identification Number (VIN) Determine from nameplate

bull Description of Component Describe major component for which the part is required For example Engine V8 260 cubic inches Transmission Automatic 5 speed Allison Model AT-545 Component identification can be determined from manufacturers component line set lists provided with all new equipment (Manufacturers line set lists should be filed in the equipment history record jacket)

bull Manufacturer of Component Give make of major component when other than make of major unit

bull Serial Number of Component Give serial number from component nameplate where applicable

bull Description of Part Give full description of part using standard nomenclature with noun name first followed by descriptive modifiers such as sprocket camshaft kit carburetor Provide the part name when available however the correct part name is the responsibility of the parts person and should be verified Part numbers should be recorded on the SRO for future reference This practice saves research time for the parts person

135 Maintenance Forms

Proper use of appropriate forms is important to keep equipment maintained

1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)

The Operators Inspection Guide and Trouble Report is used by operators of motor vehicles to indicate the items they are required to inspect before and after operation It also serves as a means of transmitting information regarding deficiencies detected

NAVEDTRA 14264A 1-13

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

physical custody or records of the Supply Department once issued to the end user

bull Provide information regarding repair parts requirements needed to support vehiclesequipment on hand or for any new vehicleequipment received (Requirements would normally be generated from actual operational experience or through normal routine inspection of equipment)

bull Furnish advance information regarding repair parts requirements for scheduled overhauls (Requirements would be generated in the same manner outlined in NAVFAC P-300 Management of Civil Engineering Support Equipment)

bull Provide technical assistance to the Transportation Shop store in identifying parts and insurance items and in determining parts interchangeability

bull Advise shop store of equipment scheduled for disposal or phase out and assist in identifying stocked items which should be eliminated from the shop store

bull In the absence of stock items provide end use Operation and Maintenance Navy (OampM N) funds to permit procurement and delivery of repair parts required for work in progress or for subsequent scheduled services and repair for which job orders have been issued

bull Conduct periodic follow-up of shop store parts orders (after required delivery date has passed) to ensure that appropriate action has been taken to reduce further delay

bull Encourage active coordinationcommunications between Public Works and Supply Department personnel

1342 Supply Department Responsibility to Public Works (Transportation)

bull Provide for the timeliest method of repair parts support through the use of available stock system stocks or purchase action using imprest fund or blanket purchase authority and indefinite delivery parts contracts (IDTC) when practical

bull Perform technical research for parts identification and to determine part numbers interchangeability and cross-referenced parts numbers

bull Collaborate with Public Works in establishing stock levels in support of current and projected vehicleequipment inventories

bull Record parts usage data for subsequent stock range and depth adjustments

bull Expedite local procurement action for immediate issue requirements when parts required are not readily available in the shop store or main supply department

bull Review outstanding requisitions regularly to ensure that status received indicates satisfactory supply action is in progress Follow up as necessary to obtain delivery status

bull Advise Public Works personnel promptly indicating delivery date(s) of requested repair parts

NAVEDTRA 14264A 1-12

bull Assume responsibility for staging of material by segregating material receipts applicable to specific repair jobs and advising the shop maintenance supervisor of material status

bull Encourage active coordinationcommunications between Supply Department and Public Works personnel

1343 Technical Parts Ordering Data

Surveys conducted by COMNAVFACENGCOM into the breakdown of repair parts support have revealed that much delay and downtime are caused by the mechanics failure to provide adequate technical data when requesting parts It should be standard practice in all maintenance shops to provide shop stores with the following information for all but common hardware and bulk material

bull Description of Major Unit Describe the vehicle or equipment unit for which the part is applicable such as Truck l2 ton 4 x 2 5000GVW

bull Manufacturer of Major Unit Give the make

bull Model of Major Unit Give manufacturers model designation

bull Year of Manufacture or Model Year Determine from nameplate

bull Vehicle Identification Number (VIN) Determine from nameplate

bull Description of Component Describe major component for which the part is required For example Engine V8 260 cubic inches Transmission Automatic 5 speed Allison Model AT-545 Component identification can be determined from manufacturers component line set lists provided with all new equipment (Manufacturers line set lists should be filed in the equipment history record jacket)

bull Manufacturer of Component Give make of major component when other than make of major unit

bull Serial Number of Component Give serial number from component nameplate where applicable

bull Description of Part Give full description of part using standard nomenclature with noun name first followed by descriptive modifiers such as sprocket camshaft kit carburetor Provide the part name when available however the correct part name is the responsibility of the parts person and should be verified Part numbers should be recorded on the SRO for future reference This practice saves research time for the parts person

135 Maintenance Forms

Proper use of appropriate forms is important to keep equipment maintained

1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)

The Operators Inspection Guide and Trouble Report is used by operators of motor vehicles to indicate the items they are required to inspect before and after operation It also serves as a means of transmitting information regarding deficiencies detected

NAVEDTRA 14264A 1-13

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  98. dQuestionCMB01PC11a1
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  99. dQuestionCMB01PC11a2
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  110. dQuestionCMB01PC14a1
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  114. dQuestionCMB01PC15a1
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  115. dQuestionCMB01PC15a2
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  118. dQuestionCMB01PC16a1
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  124. dQuestionCMB01PC17a3
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  134. dQuestionCMB01PC20a1
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  135. dQuestionCMB01PC20a2
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  138. dQuestionCMB01PC21a1
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  139. dQuestionCMB01PC21a2
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  140. dQuestionCMB01PC21a3
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  141. dQuestionCMB01PC21a4
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  142. txtRate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  143. txtCourse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  144. txtDate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  145. txtChapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  146. txtPage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  147. txtDescription
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  148. txtCorrection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

bull Assume responsibility for staging of material by segregating material receipts applicable to specific repair jobs and advising the shop maintenance supervisor of material status

bull Encourage active coordinationcommunications between Supply Department and Public Works personnel

1343 Technical Parts Ordering Data

Surveys conducted by COMNAVFACENGCOM into the breakdown of repair parts support have revealed that much delay and downtime are caused by the mechanics failure to provide adequate technical data when requesting parts It should be standard practice in all maintenance shops to provide shop stores with the following information for all but common hardware and bulk material

bull Description of Major Unit Describe the vehicle or equipment unit for which the part is applicable such as Truck l2 ton 4 x 2 5000GVW

bull Manufacturer of Major Unit Give the make

bull Model of Major Unit Give manufacturers model designation

bull Year of Manufacture or Model Year Determine from nameplate

bull Vehicle Identification Number (VIN) Determine from nameplate

bull Description of Component Describe major component for which the part is required For example Engine V8 260 cubic inches Transmission Automatic 5 speed Allison Model AT-545 Component identification can be determined from manufacturers component line set lists provided with all new equipment (Manufacturers line set lists should be filed in the equipment history record jacket)

bull Manufacturer of Component Give make of major component when other than make of major unit

bull Serial Number of Component Give serial number from component nameplate where applicable

bull Description of Part Give full description of part using standard nomenclature with noun name first followed by descriptive modifiers such as sprocket camshaft kit carburetor Provide the part name when available however the correct part name is the responsibility of the parts person and should be verified Part numbers should be recorded on the SRO for future reference This practice saves research time for the parts person

135 Maintenance Forms

Proper use of appropriate forms is important to keep equipment maintained

1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)

The Operators Inspection Guide and Trouble Report is used by operators of motor vehicles to indicate the items they are required to inspect before and after operation It also serves as a means of transmitting information regarding deficiencies detected

NAVEDTRA 14264A 1-13

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  142. txtRate
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  147. txtDescription
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  148. txtCorrection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

during inspection or operation Figure 1-2 shows the form the procedures for field application of the form follow the figure

Operatorrsquos Inspection Guide and Trouble Report Registration No

Odometer Reading

Use this form as a guide when performing before and after operation inspections Check (radic) items that require servicing by maintenance personnel

Damage (ExteriorInteriorMissing Components)

Leaks (Oil Gas Water)

Tires (Check inflation abnormal wear)

Fuel Oil Water supply (Antifreeze in season)

Battery (Check water level cables etc)

Horn

LightsReflectorsMirrorsTurn signals

Instruments (Oil Air Temperature etc)

Windshield wiper

Clean windshieldvehicle interior

Cargo mounted equipment

Steering

Safety Devices (Seat belts flares etc)

Drive BeltsPulleys

Brakes (Drain air tank when equipped)

Other (Specify in Remarks)

Date

Operatorrsquos Signature

Remarks

NAVFAC 9-1124013 (12-69) USGPO 1989-627-00180143 A-33796

Supersedes DD Form 1358

SN 0105-LF-004-1195

Figure 1-2 ndash Operatorrsquos Inspection Guide and Trouble Report (NAVFAC 9-1124013)

NAVEDTRA 14264A 1-14

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  145. txtChapter
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  147. txtDescription
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

1 Equipment dispatcher issues a form to the operator at the time of vehicle assignment

2 Operator inspects each item on the form before and after operation

3 Operator indicates by a check mark any item that does not function properly The Remarks space may be used for items not listed or for additional information concerning deficiencies indicated by a check mark

4 Operator turns in the form to the dispatcher at the end of each day unless a deficiency requiring the immediate attention of a mechanic is discovered

5 Equipment dispatcher forwards the forms to the maintenance branch for action when deficiencies are noted

6 The work input section refers the NAVFAC 9-1124013 (Operators Report) to the service writer or Maintenance Supervisor who determines if the deficiencies noted require immediate attention or if correction may be safely deferred until the next scheduled inspection If the correction is deferred the form is attached to the Service Record Card so that the deficiency may be described on the SRO when the next scheduled or unscheduled maintenance is done

1352 Shop Repair Order (SRO)

The NAVFAC 112003A (SRO) is no longer available Activities should use a computer- generated SRO such as PC Transport NFTS etc Local procedures should be developed regarding SRO copy distribution The SRO is used to do the following

bull Specifically authorize and control repair work on all types of CESE including authorization to requisition necessary repair parts from shop stores

bull Furnish basic information for management analysis

bull Authorize work on equipment when work is performed in a shop other than the activity transportation shop

bull Authorize a specific job under a Work Request (NAVCOMPT Form 140) issued by the ordering activity

bull Support the Order for Supplies or Services (DD Form 1155) as source material for the preparation of reports at small activities wholly serviced by a commercial facility

Information on the preparation and use of the SRO is detailed in NAVFAC P-300 Management of Civil Engineering Support Equipment

1353 Maintenance InspectionService Record

The Maintenance InspectionService Record NAVFAC 1120046 (Figure 1-3) is an adhesive-type sticker which is placed on the windshield dash or other conspicuous section of the equipment after each scheduled service The purpose of the form is to remind the operator of the date the equipment is scheduled for the next service It also provides information on the dates of the last oil and filter change and lubrication

NAVEDTRA 14264A 1-15

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  114. dQuestionCMB01PC15a1
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  126. dQuestionCMB01PC18a1
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  145. txtChapter
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  147. txtDescription
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

Maintenance InspectionService Record

Next Maintenance

Due MilesHours

Date

rarr When NO service is performed post data from prior sticker

Services Performed MilesHours Date

Oil Change

Filter Change

Lubricate Chassis

Service Air Cleaner

Engine Tune-Up

Smog Control Device

Safety Inspection

Last PM (circle type) A B C NAVFAC 1120046 (8-70)

Supersedes NavDocks 9-112005

Figure 1-3 ndash Maintenance InspectionService Record

1354 Operators Daily PM Report (Construction and Allied Equipment)

The Operators Daily PM Report Construction and Allied Equipment NAVFAC 112604 (Figure 1-4) is used by operators of construction and allied equipment (except weight handling equipment) as a guide when performing daily PM services and when reporting equipment deficiencies hours operated and fuel issued See NAVFAC P-307 for Operators Daily Check List of weight handling equipment The following procedures are prescribed for field application of NAVFAC 112604

1 Equipment dispatcher issues a form to the operator when the equipment is assigned

2 Equipment operator performs pre-service maintenance checks and indicates findings on the form

3 Equipment operator records malfunctions of other items requiring attention as observed during the working day

4 Equipment operator records the number of gallons of fuel issued to the equipment while in his or her custody and enters hours operated at the end of the day Hour readings should be taken from the equipment hour meter Actual operating hours should be estimated for those units not equipped with hour meters

5 At the close of business each day the form is turned in to the equipment dispatcher who reviews the form to ensure that the entries are valid and to take

NAVEDTRA 14264A 1-16

note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

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NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  1. returnTxt1CMB01PG3 Remediation Page Click anywhere on this page to return
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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note of any deficiencies reported The form is then forwarded to the maintenance dispatcher for further processing

Operatorrsquos Daily PM Report

Construction amp Allied Equipment

NAVFAC 112604

Use reverse side for Remarks

Explanatory Notes on reverse side

USN No

Operatorrsquos Daily Services

Fuel

1 Fill to proper level Remove debris from core

2 Inspect belts for proper tension alignments and condition

OPR Hrs

3 Fill to proper level inspect for leaks

4 Inspect and clean oil bath and dry type as required

5 Clean filter jar as often as conditions warrant

No Item

OK

radic Services Performed

6 Visually inspect for conditions Fill to proper level

7 Fill to proper oil levels and inspect for leaks

1 Radiator solution 8 Perform daily lubrication services as designated by the Transportation Division

2 Gen amp Fan Belt Adjusted 9 Check tire pressure with gage Inflate as necessary to recommended pressure Remove glass stones nails etc 3 Engine Oil Level

4 Air Cleaner 10 Inspect for condition safety guards boom stops radius indicators warning devices ladders fire extinguishers etc 5 Precleaner

6 Battery Added water 11 Inspect unit for general condition Correct or report any deficiencies requiring mechanics attention 7 Hyd Oil Level

8 Lubrication 12 Fill fuel tank as necessary

9 Tire Condition 13 Check all gages and meters for proper operation

10 Safety Equip 14 Perform prescribed shutdown services such as securing machines draining air tanks cover exhaust stacks close hoods etc 11 General Cond

12 Fuel Level Added 12 gal 15 List any deficiencies noted during operation

13 Instruments Remarks

14 Shutdown Precautions

15 Other

Date

121188

Operatorrsquos Signature

R R Ryan

Figure 1-4 - Operatorrsquos Daily PM Report (Construction and Allied Equipment)

NAVEDTRA 14264A 1-17

136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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136 NCF Maintenance Program under 3M Preventive Maintenance

NCF fleet maintenance accomplishment procedures are intended to provide a first-time quality product completed in accordance with the 3-M system and technical directives such as manufacturerrsquos technical manuals and technicalservice bulletins Maintenance accomplishment is a direct function of four basic elements

1 Training and qualification of the craftsmen who will perform the maintenance

2 Supervision including the direct oversight of the maintenance being performed of the individual craftsmen assigned to accomplish the maintenance

3 Formal Work Procedures (FWP) outlined in our standard MRCs which provide the necessary sequence of actions that the individual uses to complete maintenance tasks

4 Work Process a series of actions planned and executed to accomplish a unit task The work process can range from planning and executing planned maintenance to major component replacement andor restorationrepair Understanding work processes and their quality control elements is the fundamental core of a successful Quality Control Program These elements form the cornerstone of the NCF CESE Maintenance Program and are essential to ensure that all maintenance is completed per applicable technical and administrative requirements and manuals

Quality Control (QC) and Quality Assurance (QA) are integral parts of Preventive Maintenance QC and QA are discussed in depth in COMFIRSTNCDINST 112002 Naval Construction Force Equipment Management Instruction

137 Scheduled and Corrective Maintenance

Preventive Maintenance should continue as scheduled Joint spot checks of the 3-M maintenance process should be performed by WCS Maintenance Division Chiefs Departmental 3-MAs and Department Heads while the maintenance is performed on 20 percent of active and 100 percent of inactive CESE and the scheduled PMS Corrective maintenance should be documented as required using MICROSNAPOMMS Repairs should be completed only for safety repairs that are critical to the equipmentrsquos operation This work should be accomplished with minimum deferred work depending on repair parts availability and time allotted Major body and paintwork will be identified in the CSMP using the 47902K and deferred during the Battalion Equipment Evaluation Program (BEEP)

138 SKED

SKED and MicroSNAP user information should be exchanged and updated to reflect incoming personnel ensuring all key personnel have a firm understanding of 3-M system programs All outgoing personnel will be deactivated or removed from systems as required

SKED is a PMS Scheduler which generates required Preventative Maintenance Schedules for afloat work centers It reads equipment names for each work center directly from a CD saving Sailors from tedious manual entries The program generates schedules using logic based on calculations derived from periodicity rules users can interactively change these computer-generated schedules NAVEDTRA 14264A 1-18

139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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139 MicroSNAP

MicroSNAP is a logistics management information system that automates equipment configuration equipment maintenance requirement requisition receipt inventory and financial functions for afloat and shore activities

140 Types of Maintenance

141 First Echelon Maintenance

The borrowing unit performs all maintenance as prescribed by the 3M System Costs for Petroleum Oil and Lubricants (POL) and consumables required to perform these actions are borne by the borrowing unit

142 Scheduled Preventive Maintenance

The borrowing unit provides the labor required to perform the PM as prescribed by the 3M System The loaning unit provides the parts required to complete the maintenance action

143 Inactive Equipment Maintenance (IEM)

Due to varying tasking from one deployment to the next deployed units often have CESEMHE on hand which are not used for extended periods during deployment This extra equipment consumes maintenance man-hours and funds and often suffers deterioration from exposure to the elements Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for a period of time covering thirty (30) days or more Refer to NAVSEAINST 47908 and COMFIRSTNCDINST 47901

1431 Status I

Equipment that will remain on board and will be inactive for thirty days or longer and is not scheduled for corrective maintenance or overhaul

1432 Status II

Equipment that is inactive for thirty days or longer and is directly subject to corrective maintenance overhaul or removal for safe storagereplacement

150 Repair Orders The Navy uses repair orders to specify authorize and control repairs on all USN-numbered equipment The repair orders also serve as a reporting document from which information can be extracted to provide an activity with a complete picture of how their maintenance program is doing They also provide complete historical cost and utilization information for each piece of CESE therefore the information contained on the repair orders must be neat complete and accurate This cannot be overemphasized

151 Reporting Methods

3M requires all afloat activities report deferred and completed maintenance actions configuration changes configuration file corrections and Consolidated Seabee

NAVEDTRA 14264A 1-19

Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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Allowance List (COSAL) Feedback Reports As directed by Type Commander (TYCOM) or higher authority 3M work centers at shore activities are to report corrective maintenance and configuration changes on all installed shipboard-identical equipment and equipment installed in service crafts and boats

1511 Manual Reporting Methods

The configuration and maintenance forms used for manual reporting are the Ships Configuration Change Form Operational Navy (OPNAV) 4790CK the Shiprsquos Maintenance Action Form OPNAV 47902K Work Candidate and the Supplemental Form OPNAV 47902L

Appendix B of NAVSEAINST 47908B shows examples of how to document corrective and preventive maintenance actions For nuclear alterations consult TYCOM directives for CSMP procedures

1512 Automated Reporting Methods

MDS automated data reporting is basically the same as in the non-automated 3-M program The terms 2K CK and ldquoWork Candidaterdquo are perpetuated in supporting software even though the paper forms are not filled out (with the exception of the Supplemental Form OPNAV 47902L)

Transactions are entered into the computer and up-line reported by using applicable software Software instructions are developed and distributed by the 3-M Central Design Activities (CDAs) and supplemented by TYCOM instructions as required Options are available in the systems to print simulated OPNAV 47902K OPNAV 4790CK and Work Candidate forms when desired Check the applicable systems user manual or Online Help for additional information

With an automated information system the computer will provide online access to the data for identifying equipment and ordering parts When documenting requirements many of the data elements required for corrective maintenance and configuration change reporting such as the Allowance Parts List (APL) Equipment Identification Code (EIC) Equipment Name and Location will be pre-filled and displayed when the applicable equipment is identified

1513 Data Elements

Appendix A of NAVSEAINST 47908B provides the data elements and allowed values (if applicable) for each type of reporting

160 Equipment History Jackets An Equipment History Jacket is maintained for each USN-numbered item of CESE and each USNG-numbered ISO container The History Jacket should contain the respective vehicles pertinent descriptive data and maintenance history The descriptive data includes the appropriate DOD Property Record DD Form 1342 and Equipment Attachment Registration Records NAVFAC Form 6-1120045 if applicable The maintenance history includes the completed PM Record Cards NAVFAC Form 112406 and completed OPNAV 47902K and OPNAV 4790CK or computer-generated equivalent

NAVEDTRA 14264A 1-20

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  147. txtDescription
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

When a vehicle is transferred remove the current PM Record Card from the PM group file and return it to the History Jacket Then either hand carry or forward the jacket by certified mail to the receiving custodian When a vehicle is transferred to a Property Disposal Office (PDO) the History Jacket should accompany it All units that receive equipment by direct delivery from the manufacturer are required to establish the initial Equipment History Jacket

Test your Knowledge (Select the Correct Response)1 What person is responsible for the maintenance program in a Naval Mobile

Construction Battalion A Inspector B Maintenance Supervisor C Work Center Supervisor D Work Center Supervisor (3M)

2 (True or False) Corrective maintenance is that maintenance which is performed in any designated maintenance shop A True B False

3 What NAVFAC manual provides instructions for using an SRO

A P-300 B P-307 C P-405 D P-445

4 (True or False) Equipment should be placed in IEM when there is no foreseeable operational need for the equipment for sixty (60) days or more A True B False

200 MAINTENANCE SUPPORT The tools consumables and spare parts needed to support the equipment allowance of the unit are portions of maintenance support The Supply Department is responsible for providing these items

In a battalion the Supply Department is under the control of the supply officer who is assisted by a Chief Storekeeper The supply section (S-4) is responsible for general supply shiprsquos service material control and delivery The material control section is responsible for ordering receiving and controlling tools materials and repair parts

210 Repair Parts Support The individual WCS relies on the Repair Part Petty Officer (RPPO) to provide Automotive Repair Parts (ARP)

NAVEDTRA 14264A 1-21

211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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211 Detachment Repair Parts Petty Officer (DET RPPO)

The DET RPPO maintains the Details Detachments for Training (DFT) or Detachment repair parts status and accountability records and is the liaison between the main body supply office and the Details DFT or Detachment All requisitions for not in stock (NIS) and not carried (NC) materials must pass though the DET RPPO who maintains the repair parts summary sheets

212 Support Criteria

In the NCF a wide range of CESE is used Because of the different design characteristics of each of these CESE items different repair parts are required to meet the support requirements The NCF initial outfitting repair parts is designed to support new or like-new CESE for the first 1200 construction hours and is computed as two 10-hour shifts seven days per week for the first 60 days of deployment

2121 Allowance Parts List

The initial outfitting of repair parts is designed so that each CESE item has a list of parts an Allowance Parts List (APL) From this data a publication called a COSAL is prepared and distributed to the NCF unit being supported plus one copy to the requesting Command and one copy to the Naval Facilities Expeditionary Logistics Center The Naval Facilities Expeditionary Logistics Center (NFELC) draws the required initial outfitting parts peculiar called Modifier Code 98 kit and parts common called Modifier Code 96 kit and Modifier Code 97 kit and packages and ships the parts to the unit Note that in correspondence the Consolidated Parts List is referred to as the COSAL the repair parts peculiar as the Mod 98 and the repair parts common as the Mod 96 and Mod 97

2122 Special Operating Units (SOU) New Receipts

SOUs receive initial parts support for new receipts upon submission of the DD Form 1342 Department of Defense (DOD) Property Record to NFELC Code 1575 Stock replenishment thereafter is the userrsquos responsibility

213 Levels of Support

Each repair part listed on an APL is assigned a three digit maintenance code that identifies one of four levels of support O G H or D

bull First digit is the lowest maintenance level authorized to remove the item

bull Second digit indicates the lowest maintenance level authorized to repair the item

bull Third digit indicates the lowest maintenance level authorized to dispose of the item

2131 Level of Support and Definitions

bull Level O Major detachments with a maintenance capability as defined in P-300 Chapter 4 paragraph 4-22b

bull Level G Major detachments with an intermediate level maintenance capability

bull Level H Main bodies with an intermediate maintenance capability as defined in NAVEDTRA 14264A 1-22

P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

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NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  1. returnTxt1CMB01PG3 Remediation Page Click anywhere on this page to return
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
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P-300 Chapter 4 paragraph 4-22b(2)

bull Level D Depot level maintenance not currently used by the NCF

NOTE

Each higher level of support includes all lower levels For example H level includes O and G level items When the second digit is Z the item is non-repairable and should be condemned and disposed of at the level indicated in the first position maintenance code column

214 Categories of Repair Parts

Two basic types of repair parts are parts peculiar and parts common

2141 Repair Parts Peculiar

Parts applicable to a specific make and model of equipment are Repair Parts Peculiar All parts peculiar to a unit are listed on the APL

2142 Repair Parts Common

Common and consumable supplies that can be used on numerous types of equipment are Repair Parts Common These items have been separated into a Repair Parts Common Assembly (NAVSUP Modifier 96 and 5-7 Modifier 97 kits) to reduce overstocking that could occur if these items were carried within separate Repair Parts Peculiar Allowance Parts Lists The Mod 96 and Mod 97 kits are designed to supplement Repair Parts Peculiar for the first 60 days or 1200 construction hours of a contingency operation The Mod 97 kits are packaged as Modular Assemblies A Mod 97 kit consists of 29 different kits Mod 96 kit consists of 19 different kits each of which has been assigned an individual APL number This allows Repair Parts Common Assemblies to be printed in the same COSAL format and arrangement as Mod 98 kits Also illustrated NFELC catalogs are provided called NAVSUP Modifier Code 96 and 97 Catalogs

215 MicroSNAP Maintenance and Operations Support System (MOSS)

MicroSNAP MOSS is the replacement for the Seabee Automated Mobile Management Equipment Operations and Equipment Maintenance Systems Implementation of MicroSNAP MOSS to the NCF sites took place during FY00 Micro SNAP MOSS is a state-of-the-art system designed to manage vehicle inventory maintenance and operations The subsystem allows for the scheduling of preventive maintenance (PM) as well as recording corrective maintenance

MicroSNAP MOSS can be configured to operate as a single subsystem or it can be set up as two separate subsystems one for Maintenance and the other for Dispatch Operations Additionally it operates on a standalone PC or on a Local Area Network (LAN) MicroSNAP MOSS also provides a direct interface with the MicroSNAP Supply and Financial Management (SFM) subsystem if operating on the same hardware Specific instructions for enteringupdating data and generating various maintenance and dispatch reports and for using all other functions are provided in the F1 Help (screen and field help) menu option of the system

NAVEDTRA 14264A 1-23

There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

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_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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There are specific options within MicroSNAP MOSS

bull Configuration Data Allows review of the Equipment Configuration Maintenance Actions Collateral Equipment Attachment Information and Order Parts Allows authorized users to add modify or delete vehicle configuration records and associated attachments collateral equipment and maintenance actions

bull Off-site Data Exchange Provides for the transfer of specific equipment configuration data and collateral equipment data between Maintenance and Dispatch Operations when MicroSNAP MOSS is configured as two separate subsystems It also provides for downloading closed maintenance actions

bull Reports Provides options for generating online or printed forms and reports dealing with vehicle configuration maintenance and dispatch

bull Tech-Edit Provides access to a variety of functions for processing Supply RequisitionsPurchase Orders when the MicroSNAP SFM subsystem is not installed

bull Subsystem Manager Allows for establishingmaintaining of Sitesrsquo Unique data including PM settings for Active and Live Storage equipment Allows for establishing and maintaining valid users and the access rights to various functions

bull Dispatch Operations Provides for the daily dispatch and return operations of vehicles

bull Manage Direct Turnover (DTO) Parts Allows for ordering and issuing of DTO parts Provides sequential records and proof of order of all parts requests

bull Maintenance Supervisor Review Allows the Maintenance Supervisor to review and approvedisapprove the Configuration and Live Storage changes initiated by the Work Center Supervisor and Departmental 3M Assistant

bull Interfaces with MicroSNAP SFM Order requests are sent directly to MicroSNAP SFM for approval and processing Stock checks can be performed for MicroSNAP MOSS Provides direct access to MicroSNAP SFM for ordering of non-maintenance related supplies

216 COSAL Arrangement

COSAL arrangement and COSAL Allowance Changes are documented in NAVFAC P-300 Management of Civil Engineering Support Equipment

217 Technical Manuals

An effective equipment management program needs technical data and guides for each item of equipment Within the NCF operator manuals lubrication charts parts manuals and shop repair manuals are included in each units parts peculiar COSAL under NNFELC Hueneme local stock number 0NL-7610-LL-Lxx-xxxx The quantity of technical manuals (TM) is determined by the same methods used for repair parts This provides one copy for each piece of equipment of the same make and model assigned to the unit two copies for two pieces of the same make and model three copies for three to eight pieces of the same make and model and four copies for nine to twenty pieces of the same make and model equipment NAVEDTRA 14264A 1-24

2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
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2171 Naval Facilities Expeditionary Logistics Center Responsibilities

The NFELC directs and administers the technical manual support program for NCF Units and requires equipment manufacturers to furnish the appropriate TMs with every purchase These TMs can be the following types

bull Military (US Army USMC USAF)

bull Commercial (standard manufacturers)

bull Modified Commercial (standard manufacturers TMs modified to meet specific requirements)

bull Based on COSAL computations NFELC Port Hueneme provides TMs to NCF units with the repair parts pack up

2172 Manual Maintenance

All NCF units must maintain all TMs listed in their COSAL Inventory control of TMs must be maintained through periodic inventories and checkout procedures because replacement manuals for older equipment are usually hard to obtain Manuals in excess of COSAL quantities must be returned to NFELC Hueneme marked for M3 Stock If the COSAL lists incorrect TMs or does not list all the required TMs submit a NAVSUP Form 1220-2 to NFELC in accordance with P-300 paragraph 543 Replace technical manuals that are lost damaged worn out or otherwise unserviceable by submission of funded requisitions to NNFELC Port Hueneme The requisitions should include the TM stock numbers from the COSAL If not available provide all TM identification and equipment identification that includes USN number make model year of manufacture serial numbers and original procurement contract number

220 Using Part Numbers To identify the part you need you must use part numbers There are two types of part numbers manufacturerrsquos part numbers and national stock numbers

221 Manufacturerrsquos Part Numbers

Manufacturerrsquos part numbers are those used by the manufacturer of a piece of equipment to identify each part on that piece of equipment These part numbers are usually a combination of letters and numbers or all numbers

222 National Stock Numbers (NSN)

Effective September 1974 the United States agreed to replace its federal numbering system with a new 13-digit system that conforms to the NATO stock numbering format This system is known as the NSN system The 13-digit NSN is broken down into four major groups The first four digits of the NSN are the Federal Supply Classification (FSC) that groups similar items into classes The last 9 digits of the NSN are the National Item Identification Number (NIIN) The first 2 digits of the NIIN identify the NATO country that cataloged the item and the last 7 digits identify the item

As pointed out above NSN numbers provide you with the federal class of the item (first 4 digits) what country cataloged the item (digits 5 and 6) and the item identification number (last 7 digits)

NAVEDTRA 14264A 1-25

Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
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Part III of the COSAL is the section used to cross reference manufacturerrsquos part numbers to NSNs

230 Repair Parts Petty Officer Log (RPPO) The RPPO log provides a cross-index between the requisition number the department order number and the USN number

This cross-reference allows the RPPO clerk to determine the appropriate USN number for the part that was ordered This is invaluable for follow-up actions in the event of lost or misfiled requisitions shipping documents and partial or duplicate parts shipments The columns required to maintain an effective RPPO log are listed and explained below

bull Date ndash Date NAVSUP Form 1250 was submitted to supply It is indicated by the Julian date For example December 12 1996 is written 6347

bull Department Order Number ndash Internal control number assigned to each NAVSUP Form 1250 submitted to supply numbered in sequence starting with 0001

bull USN Number ndash Identifies the vehicle for which the part was ordered

bull NSNPart Number ndash NSN or part number of the ordered item

bull Item ndash Nomenclature or noun name of the item ordered

bull Unit Price ndash Price of a single item

bull Quantity ndash Total number of items ordered

bull Priority ndash Urgency-of-need Designator (A B or C)

bull NCNIS ndash Provides ready information on whether an item is Not Carried or Not In Stock

bull Requisition Number ndash Entered when the yellow copy is returned from supply All supply office documents are filed by this number

bull Follow-Up Status ndash Status furnished by supply Intervals for follow-ups should not exceed 7 days for NORSANORS 14 days for priority B and 30 days for priority C requisitions

bull Received Date ndash Date indicating when the document ordering the items was processed

bull Issued Date ndash Date item was issued to the shop for installation

Summary In this chapter you have learned to perform various administrative duties within the CM rate including opening and closing equipment repair orders maintaining history jackets updating preventive maintenance record cards and ordering DTO or repair parts

NAVEDTRA 14264A 1-26

Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

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(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
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Review Questions (Select the Correct Response)1 Guidelines for the maintenance of equipment assigned to the NCF are contained

in what NAVFAC publication

A P-280 B P-300 C P-315 D P-458

2 The equipment maintenance branch is normally under the overall supervision of

a person having what rank A CMC B CMCS C EQCM D GS-12

3 The overall responsibility for ensuring proper maintenance and repair of all

automotive construction and materials handling equipment assigned to an NMCB belongs to what person A Heavy Shop Supervisor B Light Shop Supervisor C Maintenance Supervisor D Support Shop Supervisor

4 What person is responsible for Scheduled Maintenance Requirements and Preventive and Corrective Maintenance A Cost Control Supervisor B Inspector C Light Shop Supervisor D Preventive maintenance clerk

5 What person should report any unscheduled repairs to a piece of CESE to the

shop supervisor A Crew leader B Inspector C Maintenance Supervisor D Preventive maintenance clerk

6 Under normal conditions an inspector inspects an item of equipment brought into

the maintenance shop a total of how many times A One B Two C Three D Four

NAVEDTRA 14264A 1-27

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

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NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  1. returnTxt1CMB01PG3 Remediation Page Click anywhere on this page to return
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

7 What person is responsible for maintaining the repair parts summary sheets A Detachment RPPO B DTO clerk C Preventive maintenance clerk D Technical librarian

8 Which equipment services are included in organizational maintenance

A Component rebuilding and major repairs B Lubrication and minor adjustments C Major overhaul and restoration D All of the above

9 What is the primary objective of preventive maintenance

A Ensure early detection of deficiencies B Ensure that the equipment is clean and serviceable C Maximize equipment availability and minimize repair cost D Perform minor adjustments and services

10 What type of maintenance is performed on equipment requiring major overhaul or comprehensive restoration A Operational B Organizational C Intermediate D Depot

11 NCF equipment is inspected for safety at what standard intervals

A Once every 3 months or 3000 miles B Once every 4 months or 4000 miles C Once every 6 months or 6000 miles D Once every 12 months or 12000 miles

12 What form should operators of construction and allied equipment (except weight

handling equipment) use as a guide when performing daily PM services A NAVFAC 112001 B NAVFAC 1124013 C NAVFAC 112604 D NAVFAC 1126012B

13 In an NMCB what person is responsible for general supply shiprsquos service

material control and delivery A S-2 B S-3 C S-4 D S-7

NAVEDTRA 14264A 1-28

14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Your Name and Address _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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14 When an NMCB deploys the initial supply of repair parts should support operations for how many days A 60 B 90 C 120 D 180

15 What is the lowest level of repair parts support

A O B H C G D D

16 Repair parts for use on one make and model of equipment are known by what

term A Common B Consumable C Peculiar D Specific

17 Which part of the COSAL provides a cross-reference between part numbers and

stock numbers A I B II C III D IV

18 What criterion is used to determine how many technical manuals are provided to

a unit for each type of vehicle assigned A Vehicle population B Location of the maintenance facilities C Size of the maintenance facilities D None each unit receives two copies

19 Manuals in excess of COSAL quantities must be returned to M3 stock at what

location A SPCC Mechanicsburg Pennsylvania B NFELC Gulfport Mississippi C NFELC Port Hueneme California D NFELC Davisville Rhode Island

NAVEDTRA 14264A 1-29

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description _______________________________________________________________

_______________________________________________________________

_______________________________________________________________

(Optional) Correction _______________________________________________________________

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(Optional) Your Name and Address _______________________________________________________________

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NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  149. txtName

20 What digits of the NSN indicate the FSC that groups similar items into classes

A First four digits B Digits 5 6 7 and 8 C Digits 9 10 11 and 12 D Last four digits

21 What digits in an NSN identify the country where the part was cataloged

A lst 2nd 3rd and 4th B 5th and 6th C 7th 8th and 9th D 10th 11th 12th and 13th

NAVEDTRA 14264A 1-30

Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

Rate____ Course Name_____________________________________________

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NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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Trade Terms Introduced in this Chapter Calibration The set of operations that establish under specified

conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards

Oil A liquid lubricant usually made from crude oil and used for lubrication between moving parts

Fuel The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine

NAVEDTRA 14264A 1-31

Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

3502 Goodspeed St Port Hueneme CA 93130

FAX 805982-5508

E-mail CSFE_NRTCnavymil

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NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  1. returnTxt1CMB01PG3 Remediation Page Click anywhere on this page to return
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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Additional Resources and References This chapter is intended to present thorough resources for task training The following reference works are suggested for further study This is optional material for continued education rather than for task training

Management of Civil Engineering Support Equipment NAVFAC P-300 Naval Facilities Engineering Command Washington DC 2003

Management of Weight Handling Equipment NAVFAC P-307 Naval Facilities Engineering Command Washington DC 2003

Naval Construction Force Equipment Management COMFIRSTNCD Instruction 112002 Commander First Naval Construction Division Norfolk VA 2006

Shipsrsquo Maintenance and Material Management (3M) Manual NAVSEA Instruction 47908B Commander Naval Sea Systems Command Washington DC 2003

NAVEDTRA 14264A 1-32

CSFE Nonresident Training Course ndash User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors We appreciate your help in this process If you have an idea for improving this manual or if you find an error a typographical mistake or an inaccuracy in CSFE manuals please write or email us using this form or a photocopy Be sure to include the exact chapter number topic detailed description and correction if applicable Your input will be brought to the attention of the Technical Review Committee Thank you for your assistance Write CSFE N7A

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NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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NAVEDTRA 14264A 1-33

  • NAVEDTRA 14264A_CM Basic Fullpdf
    • Instruction Page
    • CMB Cover Page
    • CMB Copyright
    • CM Table of Contents
    • CM Basic Chapter 1 Technical Administration
      • Chapter 1
      • Technical Administration
        • Topics
        • Overview
        • Objectives
        • Prerequisites
        • Features of this Manual
        • 100 MAINTENANCE ADMINISTRATION
          • 110 Maintenance Organization
            • 111 Maintenance SupervisorDivision Maintenance Chief
            • 112 Work Center Supervisor
            • 1121 Light Shop Work Center Supervisor
            • 1122 Heavy Shop Work Center Supervisor
            • 1123 Crane Crew Work Center Supervisor
            • 1124 Support Shop Work Center Supervisor
            • 113 Inspector
            • 114 Technical Librarian
            • 115 Work Center Supervisor (3-M)
              • 120 Maintenance Categories
                • 121 Organizational Maintenance
                • 1211 Operator Maintenance
                • 1212 Preventive Maintenance
                • 122 Corrective Maintenance
                • 123 Depot Maintenance
                  • 130 Maintenance Scheduling
                    • 131 Scheduling and Shop Control
                    • 132 Shop Workload
                    • 133 Non NCF Maintenance Program Shop Repair Order (SRO) Flow Procedures
                    • 134 Supply Support
                    • 1341 Public Works Responsibility to the Supply Department
                    • 1342 Supply Department Responsibility to Public Works (Transportation)
                    • 1343 Technical Parts Ordering Data
                    • 135 Maintenance Forms
                    • 1351 Operators Inspection Guide and Trouble Report (NAVFAC 9-1124013)
                    • 1352 Shop Repair Order (SRO)
                    • 1353 Maintenance InspectionService Record
                    • 1354 Operators Daily PM Report (Construction and Allied Equipment)
                    • 136 NCF Maintenance Program under 3M Preventive Maintenance
                    • 137 Scheduled and Corrective Maintenance
                    • 138 SKED
                    • 139 MicroSNAP
                      • 140 Types of Maintenance
                        • 141 First Echelon Maintenance
                        • 142 Scheduled Preventive Maintenance
                        • 143 Inactive Equipment Maintenance (IEM)
                        • 1431 Status I
                        • 1432 Status II
                          • 150 Repair Orders
                            • 151 Reporting Methods
                            • 1511 Manual Reporting Methods
                            • 1512 Automated Reporting Methods
                            • 1513 Data Elements
                              • 160 Equipment History Jackets
                                • 200 MAINTENANCE SUPPORT
                                  • 210 Repair Parts Support
                                    • 211 Detachment Repair Parts Petty Officer (DET RPPO)
                                    • 212 Support Criteria
                                    • 2121 Allowance Parts List
                                    • 2122 Special Operating Units (SOU) New Receipts
                                    • 213 Levels of Support
                                    • 2131 Level of Support and Definitions
                                    • 214 Categories of Repair Parts
                                    • 2141 Repair Parts Peculiar
                                    • 2142 Repair Parts Common
                                    • 215 MicroSNAP Maintenance and Operations Support System (MOSS)
                                    • 216 COSAL Arrangement
                                    • 217 Technical Manuals
                                    • 2171 Naval Facilities Expeditionary Logistics Center Responsibilities
                                    • 2172 Manual Maintenance
                                      • 220 Using Part Numbers
                                        • 221 Manufacturerrsquos Part Numbers
                                        • 222 National Stock Numbers (NSN)
                                          • 230 Repair Parts Petty Officer Log (RPPO)
                                            • Summary
                                            • Review Questions
                                            • Trade Terms Introduced in this Chapter
                                            • Additional Resources and References
                                            • CSFE Nonresident Training Course ndash User Update
                                                • CM Basic Chapter 2 Principles of an Internal Combustion Engine
                                                  • Chapter 2
                                                  • Principles of an Internal Combustion Engine
                                                    • Topics
                                                    • Overview
                                                    • Objectives
                                                    • Prerequisites
                                                    • Features of this Manual
                                                    • 100 INTERNAL COMBUSTION ENGINE
                                                      • 110 Development of Power
                                                      • 120 Four-Stroke-Cycle Engine
                                                        • 121 Intake Stroke
                                                        • 122 Compression Stroke
                                                        • 123 Power Stroke
                                                        • 124 Exhaust Stroke
                                                          • 130 Two-Stroke-Cycle Engine
                                                            • 200 ENGINES CLASSIFICATION
                                                              • 210 Diesel Engine
                                                                • 211 Engine Cycle Design
                                                                • 212 Cylinder Arrangement
                                                                • 213 Combustion Chamber Design
                                                                • 214 Fuel Injection System Design
                                                                  • 220 Gasoline Engine
                                                                    • 221 Operational Cycles
                                                                    • 222 Number of Cylinders
                                                                    • 223 Cylinder Arrangement
                                                                    • 224 Valve Train Type
                                                                    • 225 Cooling System
                                                                    • 226 Fuel Type
                                                                        • 300 ENGINE MEASUREMENTS and PERFORMANCE
                                                                          • 310 Definitions
                                                                            • 311 Work
                                                                            • 312 Energy
                                                                            • 313 Power
                                                                            • 314 Torque
                                                                            • 315 Friction
                                                                            • 316 Engine Torque
                                                                            • 317 Chassis Dynamometer
                                                                            • 318 Engine Dynamometer
                                                                            • 319 Mechanical Efficiency
                                                                            • 3110 Thermal Efficiency
                                                                              • 320 Linear Measurements
                                                                                • 321 Piston Displacement
                                                                                • 322 Engine Displacement
                                                                                  • 330 Engine Performance
                                                                                    • 331 Compression Ratio
                                                                                    • 332 Valve Arrangement
                                                                                    • 333 Cam Arrangement
                                                                                    • 334 Induction Type
                                                                                      • 340 Timing
                                                                                        • 341 Valve Timing
                                                                                        • 3411 Conventional
                                                                                        • 3412 Variable
                                                                                        • 342 Ignition Timing
                                                                                        • 3421 Conventional
                                                                                        • 343 ElectronicComputer
                                                                                            • Summary
                                                                                            • Review Questions
                                                                                            • Additional Resources and References
                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                • CM Basic Chapter 3 Construction of an Internal Combustion Engine
                                                                                                  • Chapter 3
                                                                                                  • Construction of an Internal Combustion Engine
                                                                                                    • Topics
                                                                                                    • Overview
                                                                                                    • Objectives
                                                                                                    • Features of this Manual
                                                                                                    • 100 ENGINE CONSTRUCTION
                                                                                                      • 110 Stationary Parts of and Engine
                                                                                                        • 111 Engine Cylinder Block
                                                                                                        • 112 Cylinder
                                                                                                        • 113 Cylinder Sleeve
                                                                                                        • 114 Cylinder Liner
                                                                                                        • 115 Water Jacket
                                                                                                        • 116 Core Hole Plug
                                                                                                        • 117 Crankcase
                                                                                                        • 118 Cylinder Head
                                                                                                        • 119 Exhaust Manifold
                                                                                                        • 1110 Intake Manifold
                                                                                                        • 1111 Oil Pan
                                                                                                        • 1112 Cylinder Head Gasket
                                                                                                        • 1113 Intake and Exhaust Gaskets
                                                                                                        • 1114 Oil Pan Gasket
                                                                                                        • 1115 Synthetic Rubber Seals
                                                                                                          • 120 Moving Parts of an Engine
                                                                                                            • 121 Piston Assembly
                                                                                                            • 122 Connecting Rods
                                                                                                            • 123 Crankshaft
                                                                                                            • 124 Camshaft
                                                                                                            • 125 Valve Train
                                                                                                            • 126 Vibration Damper
                                                                                                            • 127 Flywheel
                                                                                                              • 130 Valve and Valve Mechanisms
                                                                                                                • 131 Camshaft
                                                                                                                • 132 Followers
                                                                                                                • 133 Valve and Valve Seats
                                                                                                                • 134 Valve Guides
                                                                                                                • 135 Valve Guide Service
                                                                                                                • 136 Valve Seat Service
                                                                                                                • 137 Valve Spring Service
                                                                                                                • 138 Timing Gears
                                                                                                                  • 140 Engine Bearings
                                                                                                                    • 141 Bearing Lubrication
                                                                                                                    • 142 Bearing Characteristics
                                                                                                                    • 143 Bearing Materials
                                                                                                                        • 200 ENGINE ADJUSTMENT and TESTING
                                                                                                                          • 210 Valve Adjustment
                                                                                                                            • 211 Lifter Adjustment
                                                                                                                            • 212 Overhead Cam Adjustment
                                                                                                                            • 213 Hydraulically Operated Valves
                                                                                                                            • 214 OHC Engine Valves
                                                                                                                              • 220 Compression Test
                                                                                                                                • 221 Gasoline Engine Compression Test
                                                                                                                                • 222 Diesel Engine Compression Test
                                                                                                                                • 223 Wet Compression Testing
                                                                                                                                  • 230 Vacuum Gauge Test
                                                                                                                                  • 240 Cylinder Leakage Test
                                                                                                                                    • Summary
                                                                                                                                    • Review Questions
                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                        • CM Basic Chapter 4 Gasoline Fuel Systems
                                                                                                                                          • Chapter 4
                                                                                                                                          • Gasoline Fuel Systems
                                                                                                                                            • Topics
                                                                                                                                            • Overview
                                                                                                                                            • Objectives
                                                                                                                                            • Features of this Manual
                                                                                                                                            • 100 GASOLINE FUEL SYSTEMS
                                                                                                                                              • 110 Gasoline
                                                                                                                                              • 120 Properties of Gasoline
                                                                                                                                                • 121 Volatility
                                                                                                                                                • 122 Antiknock Quality
                                                                                                                                                • 123 Octane Rating
                                                                                                                                                  • 130 Air-Fuel Ratio
                                                                                                                                                    • 131 Lean Air-Fuel Mixture
                                                                                                                                                    • 132 Rich Air-Fuel Mixture
                                                                                                                                                      • 140 Gasoline Combustion
                                                                                                                                                        • 141 Normal Combustion
                                                                                                                                                        • 142 Abnormal Combustion
                                                                                                                                                          • 150 Gasoline Fuel System Components
                                                                                                                                                            • 151 Fuel Tank
                                                                                                                                                            • 152 Fuel Gauges
                                                                                                                                                            • 153 Fuel Filters
                                                                                                                                                            • 154 Fuel Pump
                                                                                                                                                            • 155 Fuel Lines and Hoses
                                                                                                                                                            • 156 Fuel Pressure Regulator
                                                                                                                                                            • 157 Fuel Injectors
                                                                                                                                                              • 160 Air Cleaner
                                                                                                                                                                • 200 GASOLINE FUEL INJECTION SYSTEMS
                                                                                                                                                                  • 210 Timed Fuel Injection System
                                                                                                                                                                  • 220 Throttle Body Injection System
                                                                                                                                                                  • 230 Multi-Port Injection
                                                                                                                                                                  • 240 Direct Injection
                                                                                                                                                                    • 300 EXHAUST and EMISSION CONTROL SYSTEMS
                                                                                                                                                                      • 310 Exhaust Manifold
                                                                                                                                                                      • 320 Catalytic Converters
                                                                                                                                                                      • 330 Muffler
                                                                                                                                                                      • 340 Air Injection System
                                                                                                                                                                      • 350 Positive Crankcase Ventilation (PCV) System
                                                                                                                                                                      • 360 Exhaust Gas Recirculation (EGR) System
                                                                                                                                                                      • 370 Fuel Evaporation Control System
                                                                                                                                                                      • 380 Oxygen Sensor
                                                                                                                                                                        • 381 Pre Oxygen Sensor
                                                                                                                                                                        • 382 Post Oxygen Sensor
                                                                                                                                                                        • 383 Heated Oxygen Sensor
                                                                                                                                                                            • Summary
                                                                                                                                                                            • Review Questions
                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                • CM Basic Chapter 5 Diesel Fuel Systems
                                                                                                                                                                                  • Chapter 5
                                                                                                                                                                                  • Diesel Fuel Systems
                                                                                                                                                                                    • Topics
                                                                                                                                                                                    • Overview
                                                                                                                                                                                    • Objectives
                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                    • 100 DIESEL FUEL SYSTEMS
                                                                                                                                                                                      • 110 Diesel Fuel
                                                                                                                                                                                        • 111 Diesel Fuel Oil Grades
                                                                                                                                                                                        • 112 Cetane Number
                                                                                                                                                                                        • 113 Volatility
                                                                                                                                                                                        • 114 Viscosity
                                                                                                                                                                                        • 115 Sulfur Content
                                                                                                                                                                                        • 116 Cloud and Pour Point
                                                                                                                                                                                        • 117 Cleanliness and Stability
                                                                                                                                                                                          • 120 Combustion Chamber Design
                                                                                                                                                                                            • 121 Direct Injection Combustion Chamber
                                                                                                                                                                                            • 122 Indirect Injection Combustion Chamber
                                                                                                                                                                                            • 123 Pre-combustion Chamber
                                                                                                                                                                                            • 124 Swirl Combustion Chamber
                                                                                                                                                                                              • 130 Engine Governors
                                                                                                                                                                                                • 131 Definition
                                                                                                                                                                                                • 132 Types of Governors
                                                                                                                                                                                                • 1321 Mechanical Governors
                                                                                                                                                                                                • 1322 Hydraulic Governors
                                                                                                                                                                                                • 1323 Electronic Governors
                                                                                                                                                                                                  • 140 Diesel Fuel System Components
                                                                                                                                                                                                    • 141 Tank and Cap
                                                                                                                                                                                                    • 142 Supply Pump
                                                                                                                                                                                                    • 143 Fuel Filters
                                                                                                                                                                                                    • 144 Water Separators
                                                                                                                                                                                                    • 145 Injection Pump
                                                                                                                                                                                                    • 146 Return Line
                                                                                                                                                                                                    • 147 Gauges
                                                                                                                                                                                                        • 200 METHODS of INJECTION
                                                                                                                                                                                                          • 210 Fuel Injection Systems
                                                                                                                                                                                                            • 211 Individual Pump System
                                                                                                                                                                                                            • 212 Multi-plunger Inline Pump System
                                                                                                                                                                                                            • 213 Unit Injector System
                                                                                                                                                                                                            • 214 Pressure-time Injection System
                                                                                                                                                                                                            • 215 Distributor Injection Pump System
                                                                                                                                                                                                            • 216 Common Rail Injection Pump System
                                                                                                                                                                                                            • 217 Electronically Controlled Fuel Injection System
                                                                                                                                                                                                              • 220 Caterpillar Fuel Systems
                                                                                                                                                                                                                • 221 Sleeve Metering Fuel System
                                                                                                                                                                                                                • 222 Electronic Unit Injection
                                                                                                                                                                                                                  • 230 Distributor-Type Fuel Systems
                                                                                                                                                                                                                    • 231 Injection Pump
                                                                                                                                                                                                                    • 232 Injection Pump Accessories
                                                                                                                                                                                                                    • 233 Governor
                                                                                                                                                                                                                    • 234 Nozzle
                                                                                                                                                                                                                      • 240 Cummins Diesel Fuel Systems
                                                                                                                                                                                                                        • 241 Pressure-Time Fuel Systems
                                                                                                                                                                                                                        • 242 Mechanical Electronic Unit Injector (MEUI)
                                                                                                                                                                                                                        • 243 Hydraulic Electronic Unit Injector (HEUI)
                                                                                                                                                                                                                            • 300 SUPERCHARGERS and TURBOCHARGERS
                                                                                                                                                                                                                              • 310 Superchargers
                                                                                                                                                                                                                                • 311 Centrifugal Supercharger
                                                                                                                                                                                                                                  • 320 Turbochargers
                                                                                                                                                                                                                                    • 321 Components of a Turbocharger
                                                                                                                                                                                                                                    • 3211 Turbine Wheel
                                                                                                                                                                                                                                    • 3212 Compressor Wheel
                                                                                                                                                                                                                                    • 3213 Turbine Housing
                                                                                                                                                                                                                                    • 322 Operation
                                                                                                                                                                                                                                    • 323 Advantages
                                                                                                                                                                                                                                    • 324 Lubrication
                                                                                                                                                                                                                                    • 325 Controls
                                                                                                                                                                                                                                    • 3251 Waste Gate
                                                                                                                                                                                                                                    • 326 Aftercooler
                                                                                                                                                                                                                                    • 327 Turbo Lag
                                                                                                                                                                                                                                        • 400 COLD STARTING DEVICES
                                                                                                                                                                                                                                          • 410 Coolant Heaters
                                                                                                                                                                                                                                          • 420 Lubrication Oil Heaters
                                                                                                                                                                                                                                          • 430 Glow Plugs
                                                                                                                                                                                                                                          • 440 Automatic Ether Starting
                                                                                                                                                                                                                                            • 500 DIESEL FUEL SYSTEM MAINTENANCE
                                                                                                                                                                                                                                              • 510 Dirt in Fuel System
                                                                                                                                                                                                                                              • 520 Water in Fuel System
                                                                                                                                                                                                                                              • 530 Air in Fuel System
                                                                                                                                                                                                                                                • 600 GENERAL TROUBLESHOOTING
                                                                                                                                                                                                                                                  • 610 Exhaust Smoke Color
                                                                                                                                                                                                                                                    • 611 White Smoke
                                                                                                                                                                                                                                                    • 612 Black or Gray Smoke
                                                                                                                                                                                                                                                    • 613 Blue Smoke
                                                                                                                                                                                                                                                      • 620 Quick Injector Misfire Check
                                                                                                                                                                                                                                                      • 630 Dead Cylinder Test
                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                        • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                            • CM Basic Chapter 6 Cooling and Lubricating systems
                                                                                                                                                                                                                                                              • Chapter 6
                                                                                                                                                                                                                                                              • Cooling and Lubrication Systems
                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                • 100 ENGINE COOLING SYSTEMS
                                                                                                                                                                                                                                                                  • 110 Air-Cooled Systems
                                                                                                                                                                                                                                                                    • 111 Fan and Shroud
                                                                                                                                                                                                                                                                    • 112 Baffles and Fins
                                                                                                                                                                                                                                                                    • 113 Maintaining the Air-Cooled System
                                                                                                                                                                                                                                                                      • 120 Liquid-Cooled System
                                                                                                                                                                                                                                                                        • 121 Radiator
                                                                                                                                                                                                                                                                        • 122 Radiator Hoses
                                                                                                                                                                                                                                                                        • 123 Radiator Pressure Cap
                                                                                                                                                                                                                                                                        • 124 Fan and Shroud
                                                                                                                                                                                                                                                                        • 125 Water Jacket
                                                                                                                                                                                                                                                                        • 126 Thermostats
                                                                                                                                                                                                                                                                        • 127 Expansion (Recovery) Tank
                                                                                                                                                                                                                                                                        • 128 Temperature Gauge and Warning Light
                                                                                                                                                                                                                                                                        • 129 Coolants and Antifreeze
                                                                                                                                                                                                                                                                          • 130 Servicing the Liquid-Cooled System
                                                                                                                                                                                                                                                                            • 131 Flushing the System
                                                                                                                                                                                                                                                                            • 132 Antifreeze Service
                                                                                                                                                                                                                                                                              • 140 Cooling System Tests
                                                                                                                                                                                                                                                                                • 141 Cooling System Pressure Test
                                                                                                                                                                                                                                                                                • 142 Combustion Leak Test
                                                                                                                                                                                                                                                                                • 143 Thermostat Test
                                                                                                                                                                                                                                                                                • 144 Engine Fan Test
                                                                                                                                                                                                                                                                                  • 150 Service and Repair of Cooling System Components
                                                                                                                                                                                                                                                                                    • 151 Water Pump
                                                                                                                                                                                                                                                                                    • 152 Thermostat
                                                                                                                                                                                                                                                                                    • 153 Hoses
                                                                                                                                                                                                                                                                                    • 154 Fan and Belt
                                                                                                                                                                                                                                                                                    • 155 Radiator and Pressure Cap
                                                                                                                                                                                                                                                                                        • 200 ENGINE LUBRICATING SYSTEMS
                                                                                                                                                                                                                                                                                          • 210 Purposes of Lubrication
                                                                                                                                                                                                                                                                                          • 220 Engine Oil
                                                                                                                                                                                                                                                                                            • 221 Oil Viscosity and Measurements
                                                                                                                                                                                                                                                                                            • 222 Oil Service Rating
                                                                                                                                                                                                                                                                                              • 230 Lubricating (Oil) System Components
                                                                                                                                                                                                                                                                                                • 231 Oil Pump
                                                                                                                                                                                                                                                                                                • 232 Oil Pickup and Strainer
                                                                                                                                                                                                                                                                                                • 233 Pressure Relief Valve
                                                                                                                                                                                                                                                                                                • 234 Oil Filter
                                                                                                                                                                                                                                                                                                • 235 Oil Cooler
                                                                                                                                                                                                                                                                                                • 236 Oil Pan
                                                                                                                                                                                                                                                                                                • 237 Oil Level Gauge
                                                                                                                                                                                                                                                                                                • 238 Oil Galleries
                                                                                                                                                                                                                                                                                                • 239 Oil Pressure Warning Light
                                                                                                                                                                                                                                                                                                • 2310 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                • 2311 Oil Temperature Regulator
                                                                                                                                                                                                                                                                                                  • 240 Types of Lubricating (Oil) Systems
                                                                                                                                                                                                                                                                                                    • 241 Splash
                                                                                                                                                                                                                                                                                                    • 242 Force Fed
                                                                                                                                                                                                                                                                                                    • 243 Combination Splash and Force Fed
                                                                                                                                                                                                                                                                                                    • 244 Full Force Fed
                                                                                                                                                                                                                                                                                                    • 245 Dry Sump
                                                                                                                                                                                                                                                                                                      • 250 Lubricating System Problem Diagnosis
                                                                                                                                                                                                                                                                                                        • 251 High Oil Consumption
                                                                                                                                                                                                                                                                                                        • 252 Low Oil Pressure
                                                                                                                                                                                                                                                                                                        • 253 High Oil Pressure
                                                                                                                                                                                                                                                                                                        • 254 Indicator or Gauge Problems
                                                                                                                                                                                                                                                                                                          • 260 Lubricating System Maintenance
                                                                                                                                                                                                                                                                                                            • 261 Oil and Filter Change
                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 7 Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                      • Chapter 7
                                                                                                                                                                                                                                                                                                                      • Basic Automotive Electricity
                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                        • 100 BASIC PRINCIPLES of ELECTRICITY
                                                                                                                                                                                                                                                                                                                          • 110 Composition of Matter
                                                                                                                                                                                                                                                                                                                          • 120 Composition of Electricity
                                                                                                                                                                                                                                                                                                                          • 130 Electron Theory of Electricity
                                                                                                                                                                                                                                                                                                                            • 200 ELECTRIC CURRENT
                                                                                                                                                                                                                                                                                                                              • 210 Conductors
                                                                                                                                                                                                                                                                                                                              • 220 Insulators
                                                                                                                                                                                                                                                                                                                              • 230 Semiconductors
                                                                                                                                                                                                                                                                                                                                • 231 Diodes
                                                                                                                                                                                                                                                                                                                                • 232 Zener Diodes
                                                                                                                                                                                                                                                                                                                                • 233 Transistors
                                                                                                                                                                                                                                                                                                                                    • 300 ELECTRIC MEASUREMENTS
                                                                                                                                                                                                                                                                                                                                      • 310 Ohmrsquos Law
                                                                                                                                                                                                                                                                                                                                      • 320 Voltage
                                                                                                                                                                                                                                                                                                                                      • 330 Amperage
                                                                                                                                                                                                                                                                                                                                      • 340 Resistance
                                                                                                                                                                                                                                                                                                                                      • 350 Circuit Configurations
                                                                                                                                                                                                                                                                                                                                        • 351 Automotive Circuits
                                                                                                                                                                                                                                                                                                                                        • 352 Series Circuits
                                                                                                                                                                                                                                                                                                                                        • 353 Parallel Circuits
                                                                                                                                                                                                                                                                                                                                        • 354 Series-parallel Circuits
                                                                                                                                                                                                                                                                                                                                          • 360 Circuit Failures
                                                                                                                                                                                                                                                                                                                                            • 361 Open Circuit
                                                                                                                                                                                                                                                                                                                                            • 362 Short Circuit
                                                                                                                                                                                                                                                                                                                                            • 363 Ground Circuit
                                                                                                                                                                                                                                                                                                                                                • 400 MAGNETISM
                                                                                                                                                                                                                                                                                                                                                  • 410 Electromagnetism
                                                                                                                                                                                                                                                                                                                                                  • 420 Electromagnetic Induction
                                                                                                                                                                                                                                                                                                                                                    • Summary
                                                                                                                                                                                                                                                                                                                                                    • Review Questions
                                                                                                                                                                                                                                                                                                                                                    • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                    • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                    • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                        • CM Basic Chapter 8 Basic Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                          • Chapter 8
                                                                                                                                                                                                                                                                                                                                                          • Automotive Electrical Circuits and Wiring
                                                                                                                                                                                                                                                                                                                                                            • Topics
                                                                                                                                                                                                                                                                                                                                                            • Overview
                                                                                                                                                                                                                                                                                                                                                            • Objectives
                                                                                                                                                                                                                                                                                                                                                            • Prerequisites
                                                                                                                                                                                                                                                                                                                                                            • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                            • 100 CHARGING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                              • 110 Storage Battery
                                                                                                                                                                                                                                                                                                                                                                • 111 Battery Construction
                                                                                                                                                                                                                                                                                                                                                                • 112 Battery Capacity
                                                                                                                                                                                                                                                                                                                                                                • 113 Battery Ratings
                                                                                                                                                                                                                                                                                                                                                                • 114 Battery Charging
                                                                                                                                                                                                                                                                                                                                                                • 115 Placing New Batteries in Service
                                                                                                                                                                                                                                                                                                                                                                • 116 Battery Maintenance
                                                                                                                                                                                                                                                                                                                                                                • 117 Battery Test
                                                                                                                                                                                                                                                                                                                                                                  • 120 Alternators
                                                                                                                                                                                                                                                                                                                                                                    • 121 Alternator Construction
                                                                                                                                                                                                                                                                                                                                                                    • 122 Alternator Operation
                                                                                                                                                                                                                                                                                                                                                                    • 123 Alternator Output Control
                                                                                                                                                                                                                                                                                                                                                                    • 124 Alternator Maintenance
                                                                                                                                                                                                                                                                                                                                                                    • 125 Alternator Testing
                                                                                                                                                                                                                                                                                                                                                                      • 130 Charging System Test
                                                                                                                                                                                                                                                                                                                                                                        • 131 Charging System Output Test
                                                                                                                                                                                                                                                                                                                                                                        • 132 Regulator Voltage Test
                                                                                                                                                                                                                                                                                                                                                                        • 133 Regulator Bypass Test
                                                                                                                                                                                                                                                                                                                                                                        • 134 Circuit Resistance Test
                                                                                                                                                                                                                                                                                                                                                                            • 200 STARTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                              • 210 Starter Motor
                                                                                                                                                                                                                                                                                                                                                                                • 211 Starting Motor Construction
                                                                                                                                                                                                                                                                                                                                                                                • 212 Operation
                                                                                                                                                                                                                                                                                                                                                                                    • 300 SAFETY SWITCHES
                                                                                                                                                                                                                                                                                                                                                                                      • 310 Neutral Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 320 Starter Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 330 Clutch Safety Switch
                                                                                                                                                                                                                                                                                                                                                                                      • 340 Starting Circuit Maintenance
                                                                                                                                                                                                                                                                                                                                                                                      • 350 Starting Motor Circuit Tests
                                                                                                                                                                                                                                                                                                                                                                                        • 351 Starter Current Draw Test
                                                                                                                                                                                                                                                                                                                                                                                        • 352 Starting Circuit Voltage Drop Tests
                                                                                                                                                                                                                                                                                                                                                                                            • 400 IGNITION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                              • 410 Operation
                                                                                                                                                                                                                                                                                                                                                                                              • 420 Primary Circuit
                                                                                                                                                                                                                                                                                                                                                                                              • 430 Secondary Circuits
                                                                                                                                                                                                                                                                                                                                                                                              • 440 Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                • 441 Ignition Switch
                                                                                                                                                                                                                                                                                                                                                                                                • 442 Ignition Distributor
                                                                                                                                                                                                                                                                                                                                                                                                • 443 Solid State Ignition (Replaces Ignition Coil)
                                                                                                                                                                                                                                                                                                                                                                                                • 444 Distributorless Ignition
                                                                                                                                                                                                                                                                                                                                                                                                • 445 Coil over Plug or IDI
                                                                                                                                                                                                                                                                                                                                                                                                  • 450 Spark Plug
                                                                                                                                                                                                                                                                                                                                                                                                    • 451 Spark Plug Heat Range and Reach
                                                                                                                                                                                                                                                                                                                                                                                                      • 460 Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                      • 470 Electronic Ignition System
                                                                                                                                                                                                                                                                                                                                                                                                        • 471 Electronic Ignition System Components
                                                                                                                                                                                                                                                                                                                                                                                                        • 472 Electronic Ignition System Operation
                                                                                                                                                                                                                                                                                                                                                                                                          • 480 Ignition Timing Devices
                                                                                                                                                                                                                                                                                                                                                                                                            • 481 Centrifugal Advance Mechanical
                                                                                                                                                                                                                                                                                                                                                                                                            • 482 Vacuum AdvanceElectrical
                                                                                                                                                                                                                                                                                                                                                                                                            • 483 Computerized Advance
                                                                                                                                                                                                                                                                                                                                                                                                              • 490 Ignition System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                • 491 Spark Plugs and Spark Plug Wires
                                                                                                                                                                                                                                                                                                                                                                                                                • 492 Distributor Service
                                                                                                                                                                                                                                                                                                                                                                                                                • 493 Ignition Timing
                                                                                                                                                                                                                                                                                                                                                                                                                    • 500 LIGHTING CIRCUIT
                                                                                                                                                                                                                                                                                                                                                                                                                      • 510 Headlights
                                                                                                                                                                                                                                                                                                                                                                                                                        • 511 Headlight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                          • 520 Lamps
                                                                                                                                                                                                                                                                                                                                                                                                                            • 521 Halogen
                                                                                                                                                                                                                                                                                                                                                                                                                            • 522 High Intensity Discharge (HID)
                                                                                                                                                                                                                                                                                                                                                                                                                            • 523 Light Emitting Diode (LED)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Dimmer Switch Blackout Lights (Military Application)
                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Turn-Signal Systems
                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Backup Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 560 Stop-Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Emergency Light System
                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Circuit Breakers and Fuses (Application or Uses)
                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Mini Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Conventional Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 583 Maxi Fuses
                                                                                                                                                                                                                                                                                                                                                                                                                                • 584 Circuit Breakers
                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 INSTRUMENTS GAUGES and ACCESSORIES
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Battery Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 620 Fuel Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 630 Oil Pressure Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 640 Engine Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 650 Transmission Temperature Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                      • 660 Speedometer and Tachometer
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 661 Mechanical Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 662 Electric Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                        • 663 Electronic Speedometers and Tachometers
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 670 Horn
                                                                                                                                                                                                                                                                                                                                                                                                                                          • 680 Windshield Wipers
                                                                                                                                                                                                                                                                                                                                                                                                                                            • 700 AUTOMOTIVE WIRING
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 710 One-Wire Circuit
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 720 Two-Wire Circuits
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 730 Shielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 740 Unshielded Wiring
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Wiring Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 760 Wiring Identification
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 770 Wiring Diagrams
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 780 Wire Terminal Ends
                                                                                                                                                                                                                                                                                                                                                                                                                                              • 790 Wire Support and Protection
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 9 Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 9
                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Hydraulic and Pneumatic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topic
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 HYDRAULIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 110 Basic Principles of Hydraulics
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 111 Pascalrsquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1111 Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 112 Force
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 113 Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 114 Computing Force Pressure and Area
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 115 Incompressibility and Expansion of Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 116 Transmission of Forces through Liquids
                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 117 Multiplication of Forces
                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 120 Types of Hydraulic Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 121 Petroleum-Based Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 122 Synthetic Fire-Resistant Fluids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Hydraulic System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 131 Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 132 Pumps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 133 Strainers and Filters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 134 Valves Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1341 Pressure Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1342 Directional Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1343 Volume Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 135 Actuators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1351 Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 136 Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 137 Accumulators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 138 Oil Cooler
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 139 Cooling Fan
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1310 Tubing Piping and Hose
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1311 Connectors and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1312 Sealing Materials and Devices
                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 140 Hydraulic System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 141 Oil and Filter Changes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 142 Cleaning and Flushing the System and Reservoir
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 143 Strainers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 144 Breathers Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 145 Accumulator Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 146 Control and Safety Valve Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 147 Preventing Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 148 Preventing Overheating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 PNEUMATIC SYSTEMS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Basic Principles of Pneumatics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 211 Boylersquos Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 212 Charlesrsquo Law
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 214 Compressibility and Expansion of Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 220 Pneumatic Gases
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 221 Qualities
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 222 Compressed Air
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 230 Heavy-Duty Air Compressors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 231 Compressor Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2311 Rotary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 2312 Screw
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 232 Intercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 233 Aftercoolers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 234 Receiver Tank
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 235 Pressure-Control System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 240 Air Compressor Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 241 Air Cleaner Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 242 Compressor Oil Change
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 243 Main Oil Filter Servicing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 244 Demister or Separator Element
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Contamination Control
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Potential Hazards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Safety Precautions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • CM Basic Chapter 10 Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Chapter 10
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • Automotive Clutches Transmissions and Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 100 AUTOMOTIVE CLUTCHES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 200 CLUTCH CONSTRUCTION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 210 Clutch Release Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 211 Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2111 Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2112 Cable
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 212 Hydraulic
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2121 Slave Cylinder with Clutch Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Clutch Fork
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Clutch Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Release Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Hydraulic Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Manual Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 250 Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 251 Coil Spring Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 252 Diaphragm Pressure Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 260 Clutch Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 261 Wet Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 262 Dry Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 270 Flywheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 280 Pilot Bearing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 CLUTCH OPERATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 400 CLUTCH START SWITCH
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 CLUTCH ADJUSTMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 510 Clutch Linkage Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Pressure Plate Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 530 Clutch Cable Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 540 Hydraulic Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 550 Clutch Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 551 Slipping
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 552 Grabbing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 553 Dragging
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 554 Abnormal Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 555 Pedal Pulsation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 560 Clutch Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 600 MANUAL TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 610 Transmission Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 611 Transmission Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 612 Extension Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 613 Front Bearing Hub
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 614 Transmission Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6141 Input Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6142 Countershaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6143 Reverse Idler Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 6144 Main Shaft
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 615 Transmission Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 616 Synchronizers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 617 Shift Forks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 618 Shift Linkage and Levers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 620 Transmission Types
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 621 Constant Mesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 622 Synchromesh Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 630 Auxiliary Transmissions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 640 Transmission Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 650 Transmission Overhaul
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 660 Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 670 Power Flow
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 671 Reverse Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 672 First Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 673 Second Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 674 Third Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 675 Fourth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 676 Fifth Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 AUTOMATIC TRANSMISSIONS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Torque Converters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Clutches and Bands
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 731 Multiple-Disc Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 732 Overrunning Clutch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 733 Brake Band
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 740 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 741 Pump
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 742 Pressure Regulator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 743 Manual Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 744 Vacuum Modulator Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 745 Governor Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 746 Shift Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 747 Kickdown Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 748 Valve Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 750 Automatic Transmission Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 751 Checking the Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 752 Linkage and Band Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 753 Fluid Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 754 Refilling the Transmission
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 760 Electronic Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 761 Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 762 Shift Solenoids
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 800 TRANSAXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 810 Manual Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 820 Automatic Transaxles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Trade Terms Introduced in this Chapter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 11 Drive Lines Differentials Drive Axles and Power Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 11
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Drive Lines Differentials Drive Axles and Power Train Accessories
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE LINE ASSEMBLY
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Slip Yoke (Joint)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Drive Shafts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 130 Universal Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 131 Cross and Roller Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 132 Ball and Trunnion Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 133 Double-Cardan Universal Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 140 Constant Velocity (CV) Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 141 Rzeppa CV Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 142 Tripod Joint
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 150 Center Support Bearings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 160 Drive Line Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 161 Drive Shaft Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 162 Drive Shaft Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 163 Universal Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 164 Constant Velocity Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 165 Center Support Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 DIFFERENTIALS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Differential Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 211 Differential Carrier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 212 Differential Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 213 Pinion Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 214 Ring Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 215 Spider Gears
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 220 Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 221 Spiral Bevel Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 222 Hypoid Gear
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 223 Double-Reduction Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 224 Two-Speed Final Drive
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Differential Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 231 Driving Straight Ahead
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 232 Turning Corners
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 240 Limited Slip Differentials
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 241 Clutch Pack Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 242 Cone Clutch Limited Slip Differential
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 250 Differential Service and Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 251 Differential Lubricant Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 252 Differential Gear Tooth Pattern
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 300 DRIVE AXLES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 310 Front Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 320 Rear Drive Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 330 Axle Housing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Fixed or Solid Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Semi-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 Full-Floating Axle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 350 Front Wheel Drive Axles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 360 Rear Axle Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 361 Axle Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 362 Axle Seal Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 400 TRANSFER CASES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 410 Gear Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Chain Type Transfer Case
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 430 Transfer Case Maintenance and Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 500 POWER TAKEOFFS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • CM Basic Chapter 12 Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Chapter 12
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • Construction Equipment Power Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 100 DRIVE TRAINS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 110 Mechanical Drive Trains
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 111 Planetary Gearsets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 112 Planetary Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 113 Steering Clutches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 120 Hydrostatic Drive Train
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 121 Hydrostatic Drive Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Forward
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Neutral
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1211 Reverse
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 122 Maintenance of Hydrostatic Drives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 200 TRACK and TRACK FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 210 Track Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 211 Track Chain
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 212 Track Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Track Frame
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Track Frame Rollers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Recoil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Adjusting Mechanism
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Track Guiding Guards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Maintenance of Track and Track Frame Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Track Adjustment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Shop Repairs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2341 Track Removal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 2342 Track Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 300 WINCHES and WIRE ROPE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 310 Winches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 320 Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321 Composition of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3211 Wire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3212 Strand
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3213 Core
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 322 Grades of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3221 Mild Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3222 Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3223 Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3224 Extra Improved Plow Steel Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 323 Lays of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3231 Right Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3232 Left Regular Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3233 Right Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3234 Left Lang Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3235 Reverse Lay
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3236 Lay length of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 324 Characteristics of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3241 Tensile Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3242 Crushing Strength
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3243 Fatigue Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3244 Abrasion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3245 Corrosion Resistance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 325 Measuring Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 326 Wire Rope Safe Working Load
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 327 Wire Rope Failure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 328 Handling and Care of Wire Rope
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3281 Coiling and Uncoiling
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3282 Kinks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3283 Drum Winding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3284 Fleet Angle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3285 Sizes of Sheaves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3286 Reverse Bends
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3287 Seizing and Cutting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 329 Wire Rope Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3291 Inspections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32911 External Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32912 Internal Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32913 Rejection Criteria
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3292 Lubrication
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 3210 Wire Rope Attachments
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32101 Wedge Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32102 Speltered Socket
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32103 Wire Rope Clips
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32104 Thimble
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32105 Swaged Connections
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32106 Hooks and Shackles
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32107 Eyebolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32108 Lifting Lugs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 32109 Turnbuckle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321010 Beam Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321011 Plate Clamps
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 321012 Spreader and Equalizer Beams
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 13 Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 13
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 HYDRUALIC BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Principles of Braking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 111 Vehicle Stopping Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 112 Braking Temperature
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 113 Braking Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 120 Hydraulic System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 121 Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 122 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 123 Brake Lines and Hoses
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 124 Brake Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 130 Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 131 Drum Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1311 Backing Plate
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1312 Wheel Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1313 Brake Shoes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1314 Brake Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1315 Brake Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1316 Brake Shoe Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13161 Cable Type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13162 Link type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 13163 Lever type
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 132 Brake Shoe Energization
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 133 Advantages and Disadvantages of Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1331 Advantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1332 Disadvantages
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 140 Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 141 Disc Brake Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1411 Brake Caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Disk Brake Pads
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1412 Splash Shield
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1413 Brake Disk
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1414 Calipers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14141 Floating caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 14142 Fixed caliper
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 142 Stoplight Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 143 Brake Warning Light Switch
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 144 Metering Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 145 Proportioning Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 146 Combination Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 150 Antilock Brake System (ABS)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 151 ABS Computer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 152 Hydraulic Actuator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 153 Tone Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 154 Wheel Speed Sensors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 155 ABS Operation
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 160 Power Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 161 Vacuum Boosters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1612 Released Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1613 Applied Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1614 Holding Position
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 162 Hydraulic Booster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 170 Parking Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 180 Brake System Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 181 Checking Master Cylinder Fluid Level
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 182 Brake Pedal Action
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1821 Brake Pedal Free Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1822 Brake Pedal Height
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1823 Brake Pedal Reserve Distance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 183 Brake System Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 184 Inspecting Brake Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1841 Inspecting Disc Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 1842 Inspecting Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 190 Servicing the Master Cylinder
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 1100 Servicing Drum Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1101 Servicing Wheel Cylinders
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1102 Servicing Drums
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 1103 Drum Brake Hardware Inspection
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 1110 Servicing Disk Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1111 Disk Brake Pad Replacement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1112 Servicing Caliper Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 1113 Brake Disc (Rotor) Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11131 Measuring Disc Thickness
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11132 Brake Disc Runout
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 11133 Resurfacing a Brake Disc
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 1120 Brake System Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1121 Manual Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1122 Pressure Bleeding
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1123 Vacuum
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 1124 Forced
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 200 AIR BRAKE SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 210 Compressor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 220 Governor
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 230 Unloader Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Air Tanks (Reservoirs)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 250 Brake Chambers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 260 Slack Adjusters
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 270 Brake Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 271 Treadle Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 272 Trailer Control Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 273 Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 274 Combined-Limiting and Quick-Release Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 275 Tractor Protection Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 276 Relay Emergency Valve
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 277 Check Valves
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 280 Air Hoses and Fittings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 290 System Switches and Indicators
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 291 Low-Pressure Warning Indicator
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 292 Stoplight Switches
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2100 Servicing Air Brakes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 2110 Air ABS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Basic Chapter 14 Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Chapter 14
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • Automotive Chassis and Body
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Topics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Overview
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Objectives
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Prerequisites
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • Features of this Manual
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 100 FRAMES
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 110 Integrated Frame and Body (Monocoque)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 120 Truck Frame (Ladder)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 130 Frame Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 200 SUSPENSION SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 210 Independent Suspension
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 220 Suspension System Components
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 221 Control Arms and Bushings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 222 Strut Rods
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 223 Ball Joints
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 224 Shock Absorbers and Struts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 225 Stabilizer Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 226 Torque Arms
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 230 Suspension System Springs
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 231 Spring Terminology
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 232 Leaf Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 233 Torsion Bar
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 234 Coil Spring
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 235 Air Bags
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 240 Suspension System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 241 Suspension Bushing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 242 Ball Joint Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 243 Strut Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 244 Spring Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 300 STEERING SYSTEM
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 310 Steering Linkage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 311 Pitman Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 312 Center Link
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 313 Idler Arm
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 314 Ball Sockets
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 315 Tie-Rod Assemblies
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 316 Draglink
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 320 Steering Ratio
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 330 Manual Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 331 Worm and Sector
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 332 Worm and Roller
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 333 Cam and Lever
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 334 Worm and Nut
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 335 Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 340 Power Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 341 Integral Piston (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 342 External Cylinder (Linkage Type)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 343 Power Rack and Pinion
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 400 STEERING SYSTEM MAINTENANCE
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 410 Steering Linkage Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 411 Idler Arm Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 412 Tie-Rod End Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 420 Manual Steering System Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 421 Rack and Pinion Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 430 Power Steering System Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 431 Checking Power Steering Fluid
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 432 Servicing Power Steering Hoses and Belt
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 433 Power Steering Leaks
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 434 Power Steering Pressure Test
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 435 Bleeding a Power Steering System
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 440 Troubleshooting Steering Systems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 441 Steering Wheel Play
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 442 Hard Steering
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 443 Steering System Noises
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 500 TIRES WHEELS and WHEEL BEARINGS
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 510 Tire Construction
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 511 Bias-Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 512 Belted Bias Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 513 Radial Ply Tire
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 520 Tire Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 521 Tire Size
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 522 Load Index and Speed Rating
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 523 Maximum Inflation Pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 524 Tire Grades
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 530 Tubes
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 531 Tube Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 540 Wheels
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 541 Drop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 542 Semidrop Center Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 543 Safety Wheel
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 544 Split Wheel (2 Piece Wheel)
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 550 Lug Nuts Studs and Bolts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 560 Wheel Bearing and Hub Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 561 Nondriving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 562 Driving Wheel Assembly
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 563 Wheel-Bearing Service
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 570 Tire Repair
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 580 Preventive Maintenance
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 581 Rotating Tires
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 582 Wheel Balancing
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  • 590 Troubleshooting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 591 Tire Impact Damage
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 592 Tire Wear Patterns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 593 Tire Inflation Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 594 Tire Vibration Problems
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 595 Tire and Wheel-Bearing Noise
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • 600 WHEEL ALIGNMENT
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          • 610 Steering Geometry
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 611 Caster
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 612 Camber
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 613 Toe
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 614 Steering Axis Inclination
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 615 Toe-Out On Turns
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 616 Tracking
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • 617 Scrub Radius
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              • 620 Wheel Alignment Tools and Equipment
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 621 Turning Radius Gauges
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 622 Caster-Camber Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                • 623 Tram Gauge
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    • 700 BODY REPAIR
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 710 Body Tools
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 720 Removing Dents
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 730 Replacing Sheet Metal
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 740 Preparing the Surface for Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 750 Painting
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 760 Epoxy Fillers
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      • 770 Identification Markings
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Summary
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Review Questions
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • Additional Resources and References
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        • CSFE Nonresident Training Course ndash User Update
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX I
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX II
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • APPENDIX III
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            • CM Back Cover
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  16. tfP7W16 The set of operations that establish under specified conditions the relationship between the values of quantities indicated by a measuring instrument and the corresponding values realized by standards
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  17. btnCALIBRATION
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  18. tfP14W413 A liquid lubricant usually made from crude oil and used for lubrication between moving parts
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  19. btnOIL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  23. tfP15W136 The substance that is burned to produce heat and create motion of the piston on the power stroke of the engine
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  24. btnFUEL
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  142. txtRate
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                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  148. txtCorrection
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